Converting 5-speed to 6-speed (3B) - Check List

[Jonas_R]

Hi,

So about to convert my 5-speed to 6-speed.

Sofar this is the componenst that I have:

- 6-speed box
- gear linkage from 6-speed box
- Brackets to fix the gearbox from 6-speed
- Gear mechanism from 6-speed
- Gearknob from 6 speed and leather sack.
- New needle bearing for the flywheel.

As far as I have been able to read on the forum. I need to do the following when converting:

- Push back the propshaft 1-2cm.

- Make a small spacer that is 30mm outer diamter. But what is the thickness? I'm reading suggestion from 20, 25, 30mm? Also whta should the bolt hole size be in the spacer? I'm doing this to avoid using a new subframe?

- Should I change the slave cylinder while i'm at it?

- Also I have seen AndyP mentioned something about a new clutch hose, thus this have a part no.?

Anything else I'm missing?

[4WheelDrifter]

I've just modified your list.

- 6-speed box.
- Gear linkage from 6-speed S2.
- Brackets to fix the gearbox from 6-speed S2.
- Gear shift mechanism from 6-speed S2.
- New needle bearing for the flywheel (not compulsory, but a good idea).
- New release bearing for the clutch (not compulsory, but a good idea).
- Propshaft from 6-speed S2 Coupé or front section from S2 Avant.
- Subframe from 6-speed or V6 80/90/Coupé, or spacers for original subframe (not sure on the exact details).
- New 6-speed clutch pipe.
- Modified wiring for the reverse switch.
- Early 6-speed ProConTen bracket or ProConTen removal, (depends on the 'box).

As I've said to others, concentrate on getting the things like linkage, subframe and mounts first. Finding a 6 speed 'box is the easy part.

My slave cylinder looked fine, so I reused it. It's up to you really.
I made up a new clutch hose.

HTH

[Jonas_R]

Thanks for the update.

- New needle bearing for the flywheel (not compulsory, but a good idea).
- New release bearing for the clutch (not compulsory, but a good idea).

Got those already.

- Propshaft from 6-speed S2 Coupé or front section from S2 Avant.

As far as I can read on the forum this is not nessesary?

- Subframe from 6-speed or V6 80/90/Coupé, or spacers for original subframe (not sure on the exact details).

The details would be nice indeed, if nobody can post them, then I will do that when I do the conversion.

- Early 6-speed ProConTen bracket or ProConTen removal, (depends on the 'box).

Could you give me some more details on this?

[4WheelDrifter]

The gearbox lengths are quite different. I'm sure I noted them somewhere. A shorter propshaft is needed.

What you do with the ProConTen depends on the gearbox you get. If it's from a car with an airbag it won't have any provision for the cables. I'm not sure if you can add a bracket to a non-ProConTen gearbox. With my S4 DSY I just got rid of the ProConTen.

[Jonas_R]

The gearbox lengths are quite different. I'm sure I noted them somewhere. A shorter propshaft is needed.

What you do with the ProConTen depends on the gearbox you get. If it's from a car with an airbag it won't have any provision for the cables. I'm not sure if you can add a bracket to a non-ProConTen gearbox. With my S4 DSY I just got rid of the ProConTen.

According to this post from Jeffer it is not needed, or I'm reading it wrong?

http://www.s2forum.com/forum/showpost.php?p=66851&postcount=6

Is it fairly easy to remove the ProConTen?
Do all 3b have the ProConTen, just that my 3B had airbag installed until I removed it

[AndyP]

I remember reading that post by Jeffer, the problem is that you will be pushing the engine even further forward to make it fit, not what you need on the S2!. The ABY prop is not that expensive so that what I fitted.

[4WheelDrifter]

According to this post from Jeffer it is not needed, or I'm reading it wrong?

http://www.s2forum.com/forum/showpost.php?p=66851&postcount=6

Is it fairly easy to remove the ProConTen?
Do all 3b have the ProConTen, just that my 3B had airbag installed until I removed it

There is some movement on the CV joints on the prop, but I wouldn't like to say if that would work.

If you had an airbag then you shouldn't have ProConTen, so no need to worry about that. I'm not used to 3Bs with airbags. I think that's a LHD only thing.

[Jonas_R]

Alright will get the propshaft then Anything I should get with the shaft gasket or similar?

[Jonas_R]

Ohh yeah this is the propshaft right?


German ebay

[AndyP]

If you use the propshaft from an Avant you need to split it and use the front part only, I think?

Cheaper here:-

http://www.s2forum.com/forum/showthread.php?t=39815

[Error404]

The 5 and 6 speed prop shafts are very different lengths, i'd say about 15cm at least, you defo need the ABY front section at least

[Jonas_R]

Ok so preferbly I would need propshaft from ABY Coupe then?

Guess I will have to look for that then

If I use avant propshaft then I will have to use front part of that combined with rear s2 3b propshaft correct?

[Rocco]

there are a lot of parts to change the conversion...

2000€ will go out very easy true??


good luck Jonas

[Jonas_R]

I have not spent anything near 2000 euro. Think I will around 1100 euro.

[4WheelDrifter]

I measured the props I have, and I make the ABY item 60mm longer than the 3B.

If you use the propshaft from an Avant you need to split it and use the front part only, I think?

That's what I got. The rear section on the Avant is very short due to the long rear diff housing.

The old 3B prop looks a bit easier to service, as the universal joint bushes/bearings are circlipped in, whereas the ABY is pressed together. So IMHO it's best to keep the 3B UJ and just use just the ABY front section, and the front CV joint if you decide to keep an old one. Unless of course you get an ABY Coupé prop in good condition, then you can just swap the whole thing. Easy.

New gaskets and bolts would be a good idea. You may also need to budget for a propshaft overhaul, new centre bearing and so on, but that's all in a different thread.

Also if you get a DSY gearbox like I did, or another with an oil pump, you will need to sort out an oil cooler, pipework and whatever else.