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Thread: B6 Passat suspension swap into MK5 Jetta

  1. #1
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    B6 Passat suspension swap into MK5 Jetta

    Here are the answers that I was looking for when I wrote this post:

    What is this swap for? --> Replacing the A5/ MK5 steel front and rear spindles and front lower control arms for the lighter aluminum spindles and control arms from the B5 Passat.

    Comparative data:

    MKV Jetta track widths:
    Front: 60.6 inches
    Back: 59.8 inches

    B6 Passat track widths:
    Front: 61.1 inches ----> Passat front subframe is wider, spindles are are same size/shape as A5/MK5 Jetta.
    Rear: 61.1 inches-----> Passat rear spindles are approximately 19mm wider per side.



    Front Lower control arms - Easiest part and no modification required. Just unbolt the stock steel version and replace with aluminum arms. Great opportunity to swap in poly bushings as well

    Front Spindles - A5/MK5 and B6 Passat front spindles are almost identical size and shape. Some adaptation is required. Tie rod ends, ball joints and wheel bearings have different part numbers, but are the same on A5 and B6.
    Differences:
    --Caliper carrier bolting locations are thicker and require use of the B6 Passat Carrier bolts.
    --Passat spindles DO NOT directly work with A5 base model brakes (288mm F and 260mm R rotors) So there are two options....Either grind down the portions of the base carriers and spindles to allow them to be bolted together.... OR, upgrade to larger brakes (312mm F and 286mm R rotors or larger)
    --Even though the ball joints and tie rod ends are the same, the nuts associated with each have a built in washer that is a larger diameter on the B6 (Since B6 spindles are aluminum with steel inserts) So, use B6 tie-rod nuts and ball joint nuts.

    Rear Spindles - This is where there is the biggest difference. (I did not install these on my Jetta)
    Differences:
    --B6 Spindles are approximately 19mm wider on each side, pushing the rear wheels out the same distance. Rear shock lower mounting location on rear spindles is also shifted out approximately the same distance. Rear track width widened approximately 38mm total.
    --B6 Spindle bolting locations are all thicker material for strength. So, B6 bolts will be needed for lower shock mount, carrier bolts, lower control arm bolt, upper control arm bolt and trailing arm bolts. B6 nuts (with larger shoulder) should also be used on upper and lower control arm bolting locations.
    --Rear brake compatibility????? At this point I am not sure if A5 base model rear brakes(260mm) will work with the B6 spindles.

    I hope this is of some assistance to anyone looking into this upgrade.

    PM me for any further questions.
    Last edited by mkvjettatdi; 04-01-2013 at 11:46 PM.

  2. #2
    Editor @ NSNP nsnpadam's Avatar
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    Hopefully Ryan_P should be around from Darkside to answer soon - I know they've done a bit of suspension fettling with their MK5 Jetta so should know something....

  3. #3
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    Originally Posted by mkvjettatdi
    Figured I would get the tech section going!

    I am swapping B6 Passat front and rear aluminum spindles and front aluminum LCAs into my MK5 Jetta. I was curious if anyone else on here had accomplished the swap yet. From the research i have done, it appears that the ball joints and tie rod ends for the two cars have slightly different part #s. Is it necessary to use the Passat ball joints and tie rod ends or can u run the Jetta ones?

    I have Passat ball joints that came with the front spindles, just no Passat tie rod ends. Figured i would try to find the answer before i dive into the swap.

    Thanks in advance.
    Form what i can see and the visual inspection i gave my dad's Passat, you need the whole setup, new Tiw rods cant be too expensive!!

    should save 8kg or so a side
    DARKSIDE DEVELOPMENTS.CO.UK

  4. #4
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    Info moved to first post.
    Last edited by mkvjettatdi; 04-01-2013 at 11:45 PM.

  5. #5
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    Figured I would update this with what I have learned....Updating first post with findings.

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