5-to-6 Speed Conversion: Upgrade Your Gearbox

After careful consideration and finding a good source for a suitable gearbox, I finally decided this summer to add a 6th gear to my car. However, the final deciding factor was a sheared gear on the shift linkage (detent mechanism), which unexpectedly prevented me from shifting at all. Even Schumi once raced in 5th gear. I was stuck in 4th gear and had to struggle through city traffic.

Many TDI drivers have long enjoyed the benefit of an overdrive gear from the factory. To someone unfamiliar with it, this transmission seems like a logical adaptation to the road, and I don't understand why it's not available on the less powerful models. It actually creates a completely different driving experience, as even gears 2 through 5 reduce the engine speed by 10% compared to the old 5-speed gearbox (EBF, designed for the 110 hp TDI). When you shift into 6th gear, the vehicle becomes much quieter, and it feels significantly more relaxed, even though you're actually going much faster. The engine doesn't seem to be working as hard, according to the sensory experience.

This tire should only be used on vehicles with engines producing more than 110 horsepower, as otherwise, there may not be enough power available. I have an AHF engine with significant chip tuning. Now, according to the speedometer, it reaches approximately 235 to 240 km/h, whereas before, it was limited to 215 km/h. I haven't yet determined the actual top speed due to a lack of sufficient road and the absence of GPS/navigation.

According to my speedometer, the speeds are 20, 30, 40, 50, and 60 km/h at 1,000 RPM in gears 2 through 6. Previously, I was only managing 46 km/h in the highest gear, which represents a reduction in engine speed of about 30%. The fuel consumption is thanking me for it. It's actually quite difficult to stay below 5 liters per 100 km with frequent gear changes. The forward drive is absolutely sufficient thanks to the ample torque. I have a hill here with a 12% gradient, which can be easily tackled in 6th gear at over 120 km/h. Even from 70 km/h, a usable acceleration is available.

Okay, let's move on to the conversion: You'll need a suitable gearbox. I got a DRW gearbox from a 130 hp PD engine. In addition to that, you'll need a complete clutch assembly including the flywheel, a starter motor, a hydraulic hose, and a bracket for the shift cables. Then, you simply replace all the parts, and you're done. The result is impressive. Unfortunately, my own conversion didn't work as well as I had hoped due to a lack of proper planning. Ultimately, I achieved what I wanted, but with a slight delay.

Finally, the correct oil is added, and the test drive can begin.

Here are a few more pictures about the conversion. By the way, it really is an Audi, even though there's a VW emblem on the old transmission .