5 to 6 speed gearbox swap

[Corey]

I read somewhere that a new clutch master/slave cylinder is needed? Is it? if, then why?

The slave is advisable to change because it is such a pig to get to when the 'box is in place.

[~Delta]

Slave cylinder is definitely needed, the 5 speed slave is different to the 6 speed version. Piston / pushrod is larger, the 5 speed one works, but doesn't last very long. Don't forget the 6 speed clutch has a heavier action to the 5, the piston eventually gets overloaded, and finaly bends. Once this happens, you'll notice the clutch pedal is reluctant to return to its rest position. Finally, it gets stuck.

The master cylinder has to be replaced, nothing to do with difficulty replacing with transmission in situ, it's a different shape / size entirely.

[WabTheKing]

Slave cylinder is definitely needed, the 5 speed slave is different to the 6 speed version. Piston / pushrod is larger, the 5 speed one works, but doesn't last very long. Don't forget the 6 speed clutch has a heavier action to the 5, the piston eventually gets overloaded, and finaly bends. Once this happens, you'll notice the clutch pedal is reluctant to return to its rest position. Finally, it gets stuck.

The master cylinder has to be replaced, nothing to do with difficulty replacing with transmission in situ, it's a different shape / size entirely.

i def second this, i found out the hard way much easier to change the slave when the gear box is on the floor, - unless you enjoy being friends with mr. knuckle rash!

i also had to tap the piston 2 pledal bracket the next size up (m8 i think from m6) because the thread on the 6speed master cylinder piston is a bigger than a 5speed altho this may just be on 7A models

[Silverboy]

are this parts expensive?
So, if I understand right, the slave will work, but not 4 long, så change it..
The master can not be used what so ever.... ?

[~Delta]

Doh! I got my post the wrong way round. The master can be used (on the pedal box) but not for long.

The slave (on the transmission) can't be used even short term, I just doesn't fit, different shape / size.

[newsh]

Clear now Wab I have an RS2 subframe to suit the gearbox. You're right, this is required or a spacer will need to be made for the S2 gearbox mount.

Ok cool, understood, so I should be able to just measure the difference in height of the 5 speed mountings and make a spacer so they end up level. A bit of 2" or 3" dia. ally bar should work. Yes?

[newsh]

Doh! I got my post the wrong way round. The master can be used (on the pedal box) but not for long.

The slave (on the transmission) can't be used even short term, I just doesn't fit, different shape / size.

Right, so I need a slave cyl. that actually fits the bell housing too! and the master is not likely to last long as the ratio will have changed and it will need to use more of its travel.

Its getting more complicated by the day

[newsh]

Thanks very much for all the input on this chaps, I'm going to be pretty well prepared when I actually start the job

[archiboy24]

Ok cool, understood, so I should be able to just measure the difference in height of the 5 speed mountings and make a spacer so they end up level. A bit of 2" or 3" dia. ally bar should work. Yes?

I believe the subframe spacer needs to be 20mm thick.