The 48 frame is smaller than the OEM. Some have replaced the bracket with a universal to make it fit. I swapped with a 94R frame - exact fit. Here is an excerpt from my post:

I just swapped mine in my 2003 last night and heres what I learned:

Autozone carries 2 different models of batteries that will "fit" a Passat-

1. Duralast 94R DLG- 3 year free replacement and 8 year pro rated ~ $130.

2. Duralast 48DL - 2 year free replacement and 7 year pro rated ~$80.

The 94R is larger and heavier which means more lead and longer life. I didn't want to do this again so I went wth it. I had to ask for it specifically since it doesn't come up on their parts finder when they search by car - only by part number. I talked to 3 stores and each said they had 2 in stock, but it was only the third store that could actually find one. Figures they were the farthest from home. Maybe not a problem in other parts of the world, but there aren't a lot of VWs around here.

The 94R is also a direct fit where the 48DL is a smaller frame than the original. I used the original clamp with no modifications but I can see where you would need to get creative with the 48DL. the 94R also uses the OEM vent hose so you don't have to worry about battery gases pulling into the cabin.

This link http://www.audiworld.com/tech/elec129.shtml has some good picts of the OEM and 94R side by side and a write up of how to make the swap. For the B5.5, you won't find the screws in the windshield cover to remove it. I ended up being able to pull the old and stick in the new without removing that piece, but it was a PITA. Make sure you get the cables out of the way before you try it. I didn't need a radio code and it started right up. Oh yeah, clean the drain holes below the battery and master cylinder while you are in there. you don't even have to remove the battery tray on the 5.5 because it has a handy hole right over the drain hole.

 

ok thats a good idea, but the cost is a little excessive...pepboys quoted me 139.99 for the 94R. Is there a different size retaining clamp/bracket that will hold the battery in place? I am going to call VW tomorrow to see what they have to say.

 

ok thats a good idea, but the cost is a little excessive...pepboys quoted me 139.99 for the 94R. Is there a different size retaining clamp/bracket that will hold the battery in place? I am going to call VW tomorrow to see what they have to say.

I figured the extra $50 was well worth going a couple more years before I had to do that job again.

 

Most auto stores have a universal battery bracket (adapter). Pepboys, autozone, etc... that's what I used.

 

He's right, that's what did...it cost less than $5 and fit perfectly. And I still have the old bracket if I get a bigger battery next time.

 

Yep, I had that same problem. I ripped a piece off a 2x4 and used it to fill the gap. No problems since.

 

X2 ^^
Funny though, when my car was in for the recall on the sunroof drains and the one under the battery tray the dealer tech noted that the battery had a block of wood on the bracket for the battery on the receipt....

 

You can try flipping the oem clamp the other way. Worked for me.

 

Wow, 94R for $140 from Pep Boys?!

Do yourself a favor and just go for a Grp. 48/91 Interstate MTP-91. I replaced my 4 y/o MTP-91 for a new one last Fri for $89+ out the door, and that includes the installation from Interstate Batteries of LA (a mere 2 blocks from home)...roughly the same price I paid for mine exactly 4yrs ago in 12/04 ($85) from a batt dealer. Following the warranty, the Interstate dude priced the new one based on months used for the old (48mos x 1.72 = $82.56 + tax).

MTP-91 [examples: 1995 BMW 318i and 1990 BMW 325i and 1991 BMW 318i and 2001 Z3 (all)] Pro-rata warranty: 85 months

Weight: 38.80 pounds
Length: 11.38 inches
Width: 6.88 inches
Height: 6.88 inches
Cranking Amps: 875
Cold Cranking Amps: 700
Voltage: 12

No problems at all for fitting...the oem bracket fits perfectly, and it even has the breathing tube, just like the oem German Moll battery it originally replaced when I bought the B5 new. Oh btw, this new batt now comes with 30 months free replacement (previous unit had 18 mos free).

 

the oem battery size is a 94R.
i've had the same problem.

i don't much care as it sorta fits, so i'm cool with the $50 cheaper version.

 

the oem battery size is a 94R.
i've had the same problem.

i don't much care as it sorta fits, so i'm cool with the $50 cheaper version.

I figured with all the electronics including seat heaters, I'd be lucky to get by with the amps of the 94R.

 

I got the Varta OEM 94R at the dealer for my TDI for $118 out the door. List is $108.