TDI MK5 5 Speed Swap, 01 O2J EGR Trans Into 06 BRM. Differences Between The 01 And 06 Transmissions

I had found a lot of conflicting information on using older 5-speed transmissions in the newer MK5 platforms due to changes in a few areas but I tried to recreate the issues and for whatever reason the parts that I used ended up working so I wanted to go over all the specifics if you need to do a five-speed swap on a newer BRM TDI. This was a 2006 BRM MK5 originally a 5 speed car but needed a transmission. By switching out the clutch and slave cylinder we were able to use a 2001 O2J EGR code 5 speed in its place.

[@Indianrider65]

Ive got a 2006 Jetta Tdi my X gave to me after the divorce. I don't know why it wont start yet. Ill try to find out what it is and if it (the engine) is worth saving. If it is worth saving I'll get a diagnostic report from the tech and try to sell it online. I don't wanna have to dump a bunch of money into it bc Im still pumping my savings into the Jeep/fenuegen (ALH) swap. If anybody up there wants an 06 for parts shout bk. Like I said,....I still gotta get diagnostics. I have VCDS but I dont know what the codes mean so Ill print them out and see if the tech will give me a "rough" preview type of diagnostics before I pay to tow it to his shop at $300 tow bills.

[@TDISwaps]

Dont give up on her! They usually have pretty easy fixes

[@Indianrider65]

@@TDISwaps kzbin.info/www/bejne/oITceIyfequJoMUsi=TAeewYHNlz28YAhc

[@DeeOhEm45]

Hey just subscribed! Quick question, how hard would it be to do a swap from a 2011 tdi? I’m noticing most tdi swaps are from the older models, and didn’t know how much more complicated it’d be from the newer gen diesels. And advise or tips would be greatly appreciated!

[@TDISwaps]

The biggest problem with the newer ones comes from the additional cost of tuning and deletes along with fuel pump upgrades. You are usually over $2000 just to get the basics squared away and even start the normal swap costs of another $2-3k. Not to say they are bad, they just end up being almost double the cost for not many advantages

[@tyrellprice605]

Where do you get all of your doner vehicle's??

[@TDISwaps]

I've been collecting for years, lots of marketplace shopping, and snagging deals when I don't even need them

[@23chrisjames]

Slightly off subject but do you know how I can make a speed sensor wire longer for an auto to 6 speed 02M swap in a 2002 alh? Can’t find anything.

[@TDISwaps]

As long as the splices are good it will extend fine

[@23chrisjames]

@@TDISwaps sweet, I’ll look into extending it.

[@A2J_Tim]

I heard you can swap out 5th gear for a taller one in those older transmissions to bring the rpm down a bit more.

[@TDISwaps]

Yes I believe even the newer 02J you can do that, we actually don't benefit from it here in Wyoming with all the hills and wind though. We did a 6 speed swap in another one and the lower RPMs create enough engine load in the wind we get less mpg than the original gearing unfortunately, we only gain mpg with the 6 speed in flat ground with no wind

[@A2J_Tim]

@@TDISwaps One thing I did on my Jetta to gain mpg was going to a narrower tire I went from 205 down to a 185, less contact patch = less rolling resistance and a side effect that is beneficial is that when its snowy and icy the narrower tire provides more traction because there is more PSI on the contact patch which improves grip. The down side is was the tire was a little bit shorter requiring more rpm to maintain speed, but as you said more rpm sometimes nets better fuel economy. The other thing I notices is the car accelerated faster with the narrower shorter tire but a shorter tire is like going to a lower gear ratio.

[@TDISwaps]

@A2J_Tim yes I actually just went from a 245 down to a 205 on my white mk5, but raise the aspect ratio to 65 so they are actually taller than the wider wheels, we will see how they do!