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Installation of 6 speed gearbox kit into Audi A2     More info

Installation of a EuroTuning six-speed 02J gearbox conversion kit into my Audi A2 1.4 TDI 75. The purpose of this is to provide a higher cruising gear for motorway driving. Normally, top gear (5th) is a 0.75 ratio. Adding the kit would normally provide a 0.65 6th gear, but I wanted an overdrive gear, so instead I picked a very long 0.588 6th gear ratio (and also a 0.709 5th gear, since both 5th and 6th gears are replaced by the kit). As a result, the revs will drop by around 550 RPM at motorway speeds, leading to better fuel consumption and a lot less engine noise.

Note that this is a merely a video log (and mainly shows peoples backs as they work, not anything interesting...), not an instruction video! The instructions are linked below.

The installation work is being done by Vince & John from Stealth Racing in Warwickshire, UK (www.stealthracing.co.uk), and the 02J six-speed gearbox kit comes from EuroTuning s.r.o. in the Czech Republic (www.eurotuning.cz). They also do kits for other gearboxes (02A, 02B, and 02D). See the forums at the A2 Owners Club (www.a2oc.net) or the TDIClub (forums.tdiclub.com) for more information.

There was an insufficient-end-float issue, after fixing it the gears spun freely (in the following video by Vince)

Here are the links to the installation instructions from the vendor (note that if they change the location, my links will stop working):

Normal installation instructions (which need the gearbox to be disassembled, easier & safer, but more time consuming. If you are planning to change your clutch, combining the work would be a good idea):

Installation without removing the gearbox (riskier but quicker - this is how Vince did it in the video):

The following is a thread by Timmus (Tom) which describes having his faulty differential rebuilt, his gearbox reconditioned, and also the installation of the 6th gear kit into his car (as far as I know this was only the second installation of a kit into an A2, after mine). Both Tom's kit and mine were installed by Vince at Stealth Racing. Very well illustrated and described so I strongly recommend you read it if you are interested in a gearbox upgrade.

Vince also installed this 6-speed illuminated ICT gearknob for me (although it is not pictured in the video):

Tom found an alternative solution for his car, which was to buy a 6-speed gearknob from the Typ 4F Audi A6, and transfer the emblem itself (rather than the gearstick as a whole).

There are a number of other solutions possible. Here are the 6-speed kits that I have heard of (obviously the only one I have tried is the one from EuroTuning, since it had the overdrive option I wanted). These kits typically fit vans or cars with an 02A/02B/02D or 02J gearbox (VW, Audi, Seat, Skoda).

* Quaife (long established, expensive compared to E.T. or B.P.)

* EuroTuning (they have the super-long 'overdrive' option which I wanted)

* BoraParts (recently introduced)

* Gemini (no longer produce a kit)

An alternative to installing a 6-speed kit would be to exchange the whole gearbox with a 6-speed gearbox taken from another car with similar running-gear. This usually involves some work adjusting the clutch mounting etc. Here is a video by Kane326 showing the work needed (in German).

For a higher 5th (no sixth gear, and gears 1-4 staying the same), you can exchange the existing 5th gear with a longer 5th gear (leaving a big gap between 4th and the extra-long 5th). This is the cheapest approach, but can be problematic due to the big gap between 5th and 6th.

A final alternative is to find a 5 speed box with higher ratios and compatible connections (clutch plate etc), and swap it over. Another A2 owner has successfully swapped over to a BlueMotion JDD gearbox. This will give you the long 5th, but with wide-but-even gaps between all the gears. He has recorded his shift points here:

Please feel free to ask questions in the comments, I will answer quickly.

Cost effectiveness ... if your vehicle is already highly fuel efficient like mine, although it will make a big difference in the 'mpg' numbers, the actual fuel saved would be relatively small, hence payback would take a long time. However, if you drive a lot of miles in a big vehicle such as a VW T4 or T5 transporter, the payback period will be a lot quicker.

Music is Ma Vlast by Smetana.

Stealth Racing, eurotuning, Ma Vlast, Smetana, Czech, Audi A2, Six-speed, gearbox, upgrade ...