gearbox 1 full 628x356 Gearbox conversion kit

Gearbox conversion kit

Czech Republic tuning house EuroTuning has just developed a gearbox conversion kit that allows you to add a sixth gear to your five-speed ’box.

The kit does not alter the original five gears at all, and simply adds a new longer sixth gear that lowers the engine’s revs by 400-550rpm at 130km/h (depending on the ’box), lowering fuel consumption and C0² emissions in the process.

This Gearbox conversion kit is designed for cars with transversely mounted engines equipped with 02A, 02J, 02B, 02D gearboxes and, unlike other kits on the market, it can be fitted in just a few hours without the need to remove the gearbox from the car!

gearbox 2 full 628x471 Gearbox conversion kit

Anyone can fit the set by usual procedure, that means dismantle the gearbox, take it apart, fix it and mount it back. If one has knowledge of fixing gearboxes, the fitting can be done by new “revolutionary” procedure without taking the gearbox apart. This process was developed by EuroTuning.

Just detach front left wheel, dismantle side sheet metal, create an access from top (for example by dismantling air filter or battery), then the conversion can be done. That is highly faster, personal cars more less 3 hours and VW T4 6-7 hours (the access is more difficult).

gearbox 6 full 628x471 Gearbox conversion kit

Discussions on forums clear that additional installation of 6th gearbox level can be mainly convenient for VW T4, which have gearboxes with very low transmissions and so they have to have unnecessarily fast rotation speed. At the same time, the T4 vehicles „work a lot“ and this possibility could be interesting for the users not only because of improving the driving comfort but mainly because the investment returns quickly and the operating costs will subsequently decrease because of higher MPG.

Even the recently published information on VW internet server tells that to increase MPG it is necessary to achieve as low operating rpm value as possible. That is the reason why it is recommended to shift as soon as possible, so that 5th gear should be by 50-60 km/hour and 6th gear by more than 70 km/hour. Modern Volkswagen engines don’t have any problems even at rotation speed of 1500 per minute. That is why the recent Volkswagen gearboxes are 6-speed or more (usually).

gearbox 8 full 628x450 Gearbox conversion kit

There are few usual/easy procedures to how to increase MPG:

1) Extending 5th gear. This is favorite topic on VW forums, it seems to be the easiest solution, but it is problematic.

a) Detaching 5-gear wheels isn’t as easy as it looks, it requires a special detaching device, but even if one is using it, it can still be difficult to detach the 5-gear wheels.

b) If extending works, then the gearbox has a wide space between 4th and 5th gears.

That can be disadvantageous especially for VW T4 which are commercial and their operating weight can change more than among personal cars. Then, a small hill may be a problem – to shift a „long“ 5th gear, the engine must be over-revved in such a way that the supposed fuel savings are lost again, if the 5th gear can be engaged at all.

2) Buying a used 6-gear gearbox and replacing the 5-speed gearbox with it. This option seems to be advantageous from the cost perspective, but it is mostly needed to replace other parts, too (for example clutch, flywheel, starter motor, drive shaft, etc.). You can find other parts such as the cv axle assembly at many online retailers.

Together, it can cost twice more. And because everyone looks for cheaper solutions, even if it means pre-used, which can already be defective or can brake not long after replace.

3) Next option is fitting conversion kit from 5-gear gearbox to 6-gear gearbox from a manufacturer already offering these kits, but they contain new gearbox shafts. The price is far higher, the modification requires taking apart gearboxes. It doesn’t increase MPG because these sets don’t have longer transmission.

The gearbox conversion kit by EuroTuning company doesn’t have any of these issues. It makes it possible to add the 6th longer gear without changing anything else. You still have your gearbox and other parts, so you should know their state. EuroTuning provides same warranty for their parts like the manufacturer Volkswagen.

EuroTuning tells us that there are over 350 cars out there currently running the kit, and it’s worth noting that it provides the same warranty on its parts as VW itself does.

more info on Gearbox conversion kit

The kits costs £990 plus shipping, and for more information or to place an order, log on to www.eurotuning.cz

15 Responses to Gearbox conversion kit

  1. Costica says:

    I want to buy one kit (6th gear) for 02B Eurovan transmission.
    Please advise.

    Thank you

  2. Dani Rial says:

    I need a 6th gear for 02G T4 syncro and crown wheel reduction like Seikel company done.
    Please advise

  3. Nadeem says:

    How much does this kit cost?

  4. Nadeem says:

    How much does this kit cost?

  5. eric says:

    what would be a cost for 2008 city golf

  6. bas says:

    set for an 1.4tdi gearbox in €?

  7. Csaba says:

    Hi I would like to buy this kit for my 1993 VW Eurovan 5 spd , how can I place the order ? what would be the total cost including shipping to Ontario Canada? Thanx

  8. Ramon says:

    Hello I have a 02j transmission on my 2002 volkswagen jetta 2.0 and would like to purchase a 6 speed kit for it but live in the states is it possible to ship it here?

  9. Kevin ephraim says:

    Hi
    Does the conversion fit a vw transporter t5 on a 2008 with a 1.9 tdi 5 speed.
    Thanks

  10. steven says:

    HI you say about t4 is there an chance you can by or do t5 1.9 06 6speed kits.
    course 70 mph at 3000 rpm is annoying me
    thanks

  11. Aaron King says:

    How much for the kit for be caddy 1.9 tdi 2007? And how you go about buying one?

  12. Nicolas says:

    Hey I want to know the overall cost for a vw jetta mk4 ’03. It has tdi-alh engine with 5 speed transmission.

  13. Cody says:

    Hi i have a 2p08 golf city 02J 5 speed trans. Looking for the 6th gear setup. How do i go about doing so?

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