The 1.8T six speed swap has been in the car for around a 1000KM so far. Almost everything is peachy (read about is here) but there are two problems.
Check Engine Light
The speed sensor on the gearbox was deleted. The ECU now takes vehicle speed from the ABS sensor. That got the speedo working and there doesn’t appear to be any issues doing this. But it does cause a check engine light because there is a code for the speed sensor not getting a reading.
Clearing the code only works for a couple of KMs before it comes back. Not a deal breaker for me but it’s something to bear in mind if you are thinking of doing this 1.8T 6-speed swap.
Engine Mount
The other problem is a bit more involved. The 02S 6 speed gearbox appears to mount a bit lower in the chassis. The fix for this was to turn the main part of the dog bone mount upside down and mount the thin metal bracket in the same way as before. But when you do this the metal bracket does not support the bolt in the middle that supports the dog bone.
To remedy this I used a polyurethane mount from Aliexpress but I had to modify it.
The Aliexpress mount needs to have an additional sleeve added on the round bush (gearbox side) to push the metal sleeve out by about 5mm downwards. The hole in the bracket needs to be enlarged so the main metal sleeve can go into the hole in the bracket.
First I took material out of the centre of the circular bush so the bolt could attach to the gearbox at an angle (the hole in the gearbox is at a slight angle pointing forwards). With the 02J this bolt is vertical, with the 02S the end/bottom of the bolt is a bit further forward so it slopes slightly back where it attaches to the gearbox.
The other mod was to put a spacer sleeve/collar on the bolt (on the gearbox end) so the metal sleeve supplied with the bush protrudes out from the bush by about 5mm. The hole in the metal bracket was then enlarged so the sleeve could go through the bracket. This supports the bracket. Without these mods the dog bone is not securely mounted and the shifts are jerky due to excess movement in the round bush.
The Powerflex round bush has a sleeve with a protrusion to go through the metal plate but I think this protrusion is not enough. With the 02S the angle of the bracket is less horizontal so I don’t think the bracket will fully slot over this protrusion in the sleeve.
With these mods done the engine is mounted securely and the jerking between shifts is gone.