Converting a Caddy 5-speed to a 6-speed

Hi everyone, unfortunately, I couldn't find anything using the search function. I have a 2007 Caddy with a 1.9 BLS 105hp engine, which only has the 228mm clutch with the 5-speed gearbox. I've been looking into it, and the following gearboxes should be a direct fit: JCL, JWN, GQM, JYJ, KVW, JWP, but I'm not familiar with their gear ratios. As far as I know, all of these gearboxes only use the 228mm clutch. I was wondering if it might be possible to convert the whole setup to the 240mm clutch, including the gearbox and flywheel. Has anyone ever done this before?
Currently, my clutch is slipping whenever the BLS engine receives more powerful torque.

Are there any alternatives to the 6-speed gearbox that would also fit, or that could be installed with minimal effort? My mechanic said that as long as I only use original parts, including the brackets, he will approve it.

Best regards,
Gabs

Hi,

Besides the fact that when changing gears, one should make sure that...

Make sure the gearbox fits correctly onto the engine mounts and gearbox supports!

2. The flanges for the drive shafts must match the hole pattern/diameter!

3. The drive shafts must be the correct length.

4. The teeth of the input shaft mesh correctly!

...wouldn't replacing the gearbox solve your problem!

The characteristics of a different gear ratio.
should relate to the available performance and weight.
Make sure the part fits the vehicle!

Sachs-Performance also offers sport clutches with a diameter of 228mm, which are advertised to handle a maximum torque of 420Nm .
That would have also taken care of the costs and effort involved in registering a different gearbox.

I suspect, however, that if the clutch slips under the immense torque of the BLS, then the clutch is either worn out or contaminated with oil (e.g., from a leaking seal).

Best regards, Richard.

Hi and thanks for your reply.
I understand your concerns.
This is not cheap, either.
The clutch isn't old yet, and it's dry. We've already reached 450 Nm of torque with the modifications, and the original clutch usually holds up to 400 Nm. I was just thinking that if the mounting points on the transmission and body are somewhat similar, would it be worth it for me to convert it. I understand the need for a new transmission, dual-mass flywheel (DMF), and clutch. But I was wondering if anyone has already converted to a 6-speed transmission and, in the process, perhaps switched to the larger transmission and, consequently, the larger clutch. It's also about the fact that the transmission needs to hold the torque, and that's my concern .

Best regards.

The Caddy 2k/Sa was produced with a facelift from 2003 to 2020. In the 2.0 TDI engine, for example, with 75 horsepower, there was also a 6-speed version (and many more, of course).
Accordingly, there are also the holders, original VW that fit the PP .