Golf 5 1.9 TDI 5-speed 6-speed gearbox ZMS clutch

Hello everyone,

I have a Golf 5 1.9 TDI with 77kW as a 5-speed manual. Since I will be replacing the clutch soon, and I have been wanting a 6-speed gearbox for a long time, I would like to install the 6-speed gearbox from a Golf 5 1.9 TDI. I know that the price-to-performance ratio isn't always clear-cut....

Now, to my/my questions:

- Do I also need a new ZMS for the conversion, or are they identical in the gearboxes?
- Adapt the driveshafts of the 5-speed gearbox to the 6-speed?
- Could I theoretically use the gearbox from the 2.0 TDI?


Best regards, Marco

Quote:

Now, to my questions:

First, obtain precise data and motor/gearbox specifications for the actual and desired states.

Hello everyone,

I have a Golf 5 1.9 TDI with 77kW as a 5-speed manual. Since I will be replacing the clutch soon, and I have been wanting a 6-speed gearbox for a long time, I would like to install the 6-speed gearbox from a Golf 5 1.9 TDI. I know that the price-to-performance ratio isn't always clear-cut....

Now, to my/my questions:

- Do I also need a new ZMS for the renovation, or are they identical in the gearboxes?

According to my information, these are:

Gear Number: FNE
Gear Number: FWZ
Gear Number: GQM
Gear Number: GQQ
Gear Number: HJT
Gear Number: JCR
Gear Number: JYJ

and

Number of teeth: 28
Hub profile: 20.4
Hub profile: 22.2
Diameter 1: 228 mm
Diameter 2: 228 mm


identical in terms of clutch, etc.

- Do the driveshafts of the 5-speed gearbox fit the 6-speed?

See above, this should theoretically work.


- Could I theoretically use the gearbox from the 2.0 TDI?

Probably, a lot of remodeling will be required.

Thank you in advance for your help. Where can I find the gear marking codes? The engine has the designation BKC.

Best regards
Marco

Where can I find the gear marking codes?

On the transmission or vehicle data carrier (e.g., left trunk) and in the service manual (also vehicle data label).

Found it. The gearbox has the designation: GQQ

Do I understand correctly that I can use the ZMS from the "old" gearbox in the newer 6-speed gearbox?

Best regards, Marco

Sometimes. There was the 1.9 with 5 and 6 gears. However, the 6-gear was actually just a 5 gear transmission. Although it is a bit longer, it is technically only 'slightly durable'. Since the clutches and flywheels were identical and only available for ~250NM.

Joint wave flange is 100 mm in your example.

GQM would then be, for example, the 6-speed counter-part.
With joint wave flange diameter 100 mm.


But is that really what you want?

I have the Golf 5 1.9 TDI with DPF and 6-speed transmission.
MKB: BLS
GKB: JYJ

The transmission has an extremely fine gear ratio. I often refer to it ironically as a 3-course meal with split-stage options.
And it is indeed easily operable with 2-4-6.

I don't know how long your current 5. Okay, here's the translation:

It's interesting, but here's a graph that puts it (specifically, the relatively long JMA of the 170 PS Passat) into perspective.

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[img]/download.php?id=5459[/img]

I have the Golf 5 1.9 TDI DPF with a 6-speed gearbox, so
MKB: BLS
GKB: JYJ

The transmission has an extremely fine gear ratio. I often refer to it ironically as a 3-course meal with split-stage options.
And it is indeed easily operable with 2-4-6.

I don't know how long your current 5. Okay, here's the translation:

It's interesting, but here's a graph that puts it (specifically, the relatively long JMA of the 170 PS Passat) into perspective.

m;

/download.php?id=5459


JYJ = Translation Z1 : Z2 Axis drive 61 : 18 = 3.389
GQQ = Translation Z1 : Z2 Axis Drive 61 : 18 = 3.389

Flansch shafts, both with 100mm

As far as I can tell, all 1.9TDi engines have this. The other engines are a bit different.

AH

before I forget:

The Radha's shell on the left side needs to be removed.
Our golf ball has a large hole for the 6th. Group.

I believe the 1K0 805 911 L needs to be installed.
I'll check again today - The patient is still an open case.
/viewtopic.php?t=26958#207572

m;

Hello everyone,

What is the significance of the Radha's bowl?

@dieselmartin: Ich würde mich gerne erkundigen, welche Drehzahl du mit deinem 6-Gang-Getriebe bei Geschwindigkeiten von 100 km/h, 140 km/h und 180 km/h hast.

That can be seen from his attached diagram.

The graph makes me a little suspicious... According to this, the 5th and 6th gear have EXACTLY the same gear ratio?!
I always suspected/believed that the 6-speed transmission, even if only slightly, is longer than the 5-speed transmission.

@dieselmartin: Does it actually look like this in practice? I have the following speeds:

100km/h: approximately 2000-2100
140km/h: approximately 2900-3100
180km/h: approximately 3700-3900

Best regards, Marco

PS: Currently, I'm at a point where I need to decide whether to have my transmission rebuilt, purchase a rebuilt 5-speed transmission, or switch to a 6-speed transmission. I'm not sure which option is the best for me.

Quote:

P.S.: Currently, I'm at a point where I'm considering either having my transmission rebuilt, purchasing a rebuilt 5-speed transmission, or switching to a 6-speed transmission. I'm not sure which option is the best for me.

With almost identical total translation – I don't understand the point, except to switch switch switch.... . I often find myself shifting gears too late, especially with a 6-speed transmission, because I simply don't want to shift every few seconds. In this case, I find it more uncomfortable than beneficial.

Do the gearboxes for the 2.0 TDI machines fit without modifications to the 1.9 TDI engine? Does anyone know exactly what needs to be changed? That might also be an option...

Here is the hole in the Radha's bowl.

The photo was taken from a low/high angle.

m;