Starting my project. 5spd Swap

[Jc61990]

First off. mods feel free to move this to projects & builds.

So i Have a 1999.5 Audi A4 1.8T, recently the tiptronic transmission took a turn for the worse, so this brought out the perfect opportunity to finish my 5spd swap. i had started collecting parts here and there.

So far i have

-5spd Shifter Box - 45$
-Shifter Trim
-Shifter knob - 10$
-Shifter boot
-Clutch pedal - 30$
-Brake pedal - Got with clutch pedal
-Clutch master Cylinder - 10$
-5spd Drive shaft from a 97 (carbon fiber) - 150$
-s4 steering wheel from a manual to replace my wheel with tip buttons. 25$wheel + 30$airbag
-new clock spring - 50$

i still need
-1.8T 5spd Transmission
-Slave cylinder
-Clutch and flywheel
-2x Front CV Axles
-M/T Trans Brackets
i want to get a new cluster and ECU but that will come later on if i feel liike changing them.

so since my car is now not running i decided to start digging in.
i already installed my pedals and clutch master cylinder.
today i started ripping apart my center console so i can get the shifter out once i drop the transmission. i removed the TCU, removed the steering wheel so i can replace my broken clock spring, i removed that stupid cable that locks the ingition switch unless the car is in park. now the key can be inserted and removed when ever, just like any other manual car. well heres some pics ill be updating this as i go.

lets start off with this. so usually on the brake pedal theres 2 switches a white and black, now i think the black should be moved over to the clutch and will become the clutch switch once i reprogram the ecu to be manual, if not then thats my idea down the drain. for now thats how i have it set up, ill have to see if it works after i finish.
heres the switches

http://i27.photobucket.com/albums/c166/jc61990/PICT0137.jpg
http://i27.photobucket.com/albums/c166/jc61990/PICT0138.jpg
the white is for the brake lights the other i have no clue.
http://i27.photobucket.com/albums/c166/jc61990/PICT0139.jpg
i think this would be come the clutch switch after i move it over.
http://i27.photobucket.com/albums/c166/jc61990/PICT0140.jpg
moved.

now i went after the center console. i remove it completely and started attacking the shifter, i removed the park key lock cable it was kind of a bitch but i finially got it out. i remember in chris' diy he said to just tuck it away, well it would annoy me, im ocd like that and decided to remove it.
http://i27.photobucket.com/albums/c166/jc61990/IMG_0415.jpg
center console out
http://i27.photobucket.com/albums/c166/jc61990/PICT0144.jpg
http://i27.photobucket.com/albums/c166/jc61990/PICT0143.jpg
this was pretty easy to get out theres a clip on the back of the ignition switch pull the off then it will want to come out but wont, just put the key in the ignition turn to acc and it falls right out. then the key will be able to be inserted and removed as pleased.
http://i27.photobucket.com/albums/c166/jc61990/PICT0142.jpg
more of center console ripped out

http://i27.photobucket.com/albums/c166/jc61990/photo-17.jpg
found the TCU!
http://i27.photobucket.com/albums/c166/jc61990/photo-18.jpg
everything ripped out

http://i27.photobucket.com/albums/c166/jc61990/photo-16.jpg
put it all in the trunk


now some random shots.
re plasti diped the shifter trim

before:
http://i27.photobucket.com/albums/c166/jc61990/PICT0118.jpg
after
http://i27.photobucket.com/albums/c166/jc61990/PICT0125.jpg

i also re wraped the knob and boot, its just a feeler for now idk if its gonna stay
http://i27.photobucket.com/albums/c166/jc61990/photo-15.jpg

http://i27.photobucket.com/albums/c166/jc61990/PICT0120-1.jpg
driveshaft

and thats that for now.

tomorrow i plan on trying to get the old drive shaft out and possibly droping the tranny.

also i have a 4.11 rear diff so i might swap in the 3.89 one if i can find one.

i will also be listing a few items i took out so keep an eye out for my listings if anyone with an auto needs parts.

[biketsai]

I didnt need to fix anything on my ignition setup so the key will turn. Im not so sure you needed to do that but I guess it wouldnt hurt. Your cluster should recode. Unfortunately you still have the expensive stuff to buy still.

[Jc61990]

I didnt need to fix anything on my ignition setup so the key will turn. Im not so sure you needed to do that but I guess it wouldnt hurt. Your cluster should recode. Unfortunately you still have the expensive stuff to buy still.

yea clint@rai has been working a deal with me and im also getting a deal from mike on a clutch, i shouldnt be spending much more than 1600 total. im getting the remaining parts minus clutch for 650, and im probly going to get a stock dmfw and just buy a fx400 for 450 and put it on the stock flywheel to save my self some money.

and yea my cluster fixed its self once i pulled the tcu out

http://i27.photobucket.com/albums/c166/jc61990/IMG_0405.jpg

[biketsai]

You honestly might as well get the LWFW from Mike if you have the money. Unless you can get the flywheel resurfaced for a good price without hefty shipping charges than maybe it will come out less, but for me it would have cost more to use the stock flywheel. Just my .02

[Jc61990]

okay so my friend is coming to help me this weekend hes bringing a tq wrench and a transmission jack. so im waiting till the weekend to drop the trans and pull the driveshaft, in the mean time i ordered a bunch of parts.

the only tool i didnt have was a tq wrench my friend is bringing that, i searched my toolboxes found everything except 1 socket. so heres what i bought/ ordered today

-Clock Spring - $49.99 (broke mine a while back)
-T-55 Torx socket - $6.29 Sears
-Valve Cover Gasket - $33.66 Autozone (new valve cover going on)
-Threadlocker, 242, Medium-Strength, Blue Loctite - $3.95 Summit Racing
-Moly Paste, for Camshaft Break-In and Engine Assembly - $12.25 Summit Racing
-Gear Lube, MT-90 Transmission Gear Oil, 75W90, Synthetic, 3 qts - $29.85 Summit Racing
-Gear Lube, Shockproof Heavy Gear Oil, 75W90, Synthetic, 1 qt - $10.95 Summit Racing
-Grease, CV-2, Cartridge/Tube, 14 oz. - $10.95 Summit Racing
-Brake Cleaner, 15 oz. Aerosol Can, - $5.95 Summit Racing
-Double ended 17mm hex 12pt Transmission drain plug removal tool - $25.73 Germanautoparts.com
-JHM Bushing Upgrade - $29.99 JH Motorsports
-Brake Fluid - DOT 4 Synthetic OEM replacement 1 Liter - $13.50 JH Motorsports

im going to pick up the brake fluid probly at an auto parts store.

i also emailed zorkos about the pilot bearing so when they get back to me ill place the order in the morning.

this is what i still need on the parts.. other wise im all set on tools and fluids.

-Complete 1.8t 5spd transmission
-(2) CV Axles for a manual transmission
-Clutch Flyweel and Pressure Plate
-New flywheel/pressure plate bolts needed)
-2.8 Drivers side transmission bracket PN# 8D0399113AG
-Passenger side transmission bracket from 5spd car
-Driveshaft to bellhousing bolts
-Rear crankshaft seal
-Slave cylinder
-Clutch hardline that runs from the clutch master cylinder to slave cylinder

Without the above i have so far spent about $746.55 with tax and shipping. im going to be spending another 650 on the rest of the parts with no clutch so figure $1396 after that then a clutch from mike is like 940$ soo about $2336 total. and thats only cause i spent a little more than chris and got some other things he didnt.

i should have all of that very shortly Clint@RAI is hooking me up i just need to set up a date thats good with my dad and clint so we can pick this stuff up.

i cant wait to finally finish this

[Jc61990]

Ordered even more parts today.

Since I'm changing the valve cover, I decided to fix my busted cam chain tensioner.

-cam chan tensioner & gasket - 175$ German auto parts
-cam locking tool - 40$ ecs
-high performance sealant - 6$ ecs
-4pc tripple square socket set - 16$ ecs

that's it for now I think I should be set for life on tools lol.

[A4Rob]

Moved. Nice project!

[biketsai]

Are you using stock crank shaft? What else are you fixing other than the trans?

[Jc61990]

Yea using stock cranshaft. Only fixing cam chain tensioner, replacing valve cover and clock spring

[Jc61990]

Got some stuff in the mail today. and did some work.
GermanAutoParts Trans Drain Plug tool.
http://jc-mallozzi.com/swap/IMG_0427.JPG

Clock Spring for a Manual Transmission.
http://jc-mallozzi.com/swap/IMG_0426.JPG

so first this i did was install my clock spring. i removed the airbag. with a t-30 torx theres 2 of these behind the wheel.
http://jc-mallozzi.com/swap/IMG_0441.JPG
http://jc-mallozzi.com/swap/IMG_0442.JPG
then theres 1 big nut in the middle of the wheel, i forgot the size of the bit i used. but you need some serious force to take it off.
http://jc-mallozzi.com/swap/IMG_0439.JPG
once its off u need to take the steering colum covers off
2 screws on the front and 2 under neath. all philips.
http://jc-mallozzi.com/swap/IMG_0435.JPG
http://jc-mallozzi.com/swap/IMG_0436.JPG
now that its off u can remove the bad clockspring.
http://jc-mallozzi.com/swap/IMG_0430.JPG
heres my old clock spring
http://jc-mallozzi.com/swap/IMG_0428.JPG
http://jc-mallozzi.com/swap/IMG_0429.JPG
and the new one.
http://jc-mallozzi.com/swap/IMG_0431.JPG
http://jc-mallozzi.com/swap/IMG_0432.JPG
the new one only goes in 1 way so pop it on
plug in the connector on the back.
the automatic has 2 connectors, one is for airbag/horn the other is for the tiptronic steering wheel. the manual clock spring that i now have does not have the spot for the 2nd connector so just tuck it aside.
http://jc-mallozzi.com/swap/IMG_0433.JPG
put the covers back on and screw it up.
http://jc-mallozzi.com/swap/IMG_0437.JPG
now thats its back on theres a pull clip to release the lock on the clock spring since it is centered out of the box. u need to remove this to put the wheel back on.
http://jc-mallozzi.com/swap/IMG_0438.JPG
now u can put the wheel back on and the nut.
put the airbag back in and plug it in.
http://jc-mallozzi.com/swap/IMG_0440.JPG
tighten it down.
and be amazed.
http://jc-mallozzi.com/swap/IMG_0443.JPG

it was very simple and straight forward. now my horn should work again :)


okay and i also changed my valve cover.

so i need an expert. i had this noise coming from my engine for a while now. it sounded like marbles in a blender. it was only on a cold start, lasted about 5 min and came from the back of the engine by the valves. i had like 4 people tell my my cam chain tensioner was shot.

so i ordered one last night. it will be here tomorrow. now by looking at this picture does it look bad? the chain was pretty tight too.

http://jc-mallozzi.com/swap/IMG_0445.JPG
http://jc-mallozzi.com/swap/IMG_0446.JPG



i put the valve cover on with the same gasket, i have a new one in my room im going to use when the tensioner, and some stuff i ordered from ecs gets here. but heres some shots.

http://jc-mallozzi.com/swap/IMG_0450.JPG
http://jc-mallozzi.com/swap/IMG_0451.JPG
http://jc-mallozzi.com/swap/IMG_0453.JPG
http://jc-mallozzi.com/swap/IMG_0455.JPG
http://jc-mallozzi.com/swap/IMG_0456.JPG
http://jc-mallozzi.com/swap/IMG_0454.JPG

yep. so thats about it for what i did today. tomorrow night my friend is coming with the trans jack so we can start on the trans saturday

[Sales@RAI]

damn dude I had an extra chain tensioner here I could have given you

[Jc61990]

Parts parts parts parts.

-Everything all together.
http://i27.photobucket.com/albums/c166/jc61990/PICT0151.jpg
Tranny Fluids, Pilot Bearing, Cam Chain tensioner, grease, moly paste, brake cleaner, loctite

http://i27.photobucket.com/albums/c166/jc61990/PICT0152.jpg
Special pilot bearing.

http://i27.photobucket.com/albums/c166/jc61990/PICT0154.jpg
http://i27.photobucket.com/albums/c166/jc61990/PICT0155.jpg
fluids and etc


also i think i found my cam chain tensioner problem.

look at this pic. i held my new one up to the computer screen of the pic i took and it looks like the black piece broke off.. it must be floating around in my engine or something now. Unlesss...... the new one i got is a newer model and the old one is supposed to look like that. IDK you tell me this is the first time ive ever seen a cam chain tensioner.

http://i27.photobucket.com/albums/c166/jc61990/PICT0158.jpg

[TQMB5]

definitely go with a LWFW. i didnt when i upgraded my clutch and regret it every day

[PZ.]

That's the tensioner tool. It holds the tensioner together until it is installed.

[Altech75]

definitely go with a LWFW. i didnt when i upgraded my clutch and regret it every day

This is a very good idea. If you're worried about chatter you can go with a slightly heavier flywheel, but lightweight is good. 034 offers a steel 16lb one and an aluminum 9lb one.

[Jc61990]

the clutch kit comes with 14lb steel flywheel. so i dont think i need to worry about chatter.

[AudiRacerS4]

looking good [up]

[biketsai]

the clutch kit comes with 14lb steel flywheel. so i dont think i need to worry about chatter.

I believe its like 14 or 15. But anyways, I believe you are getting the same clutch as me- Clutchmasters FX400 with a Steel LWFW (I got the 8-puck disk). I have no chatter at all and its quite nice!

[AudiRacerS4]

also I hate to break it to you JC but I looked firther into your clutch switch idea and i think its a no go unfortunately. I have the full pedal assembly out of a manual car and you can see the clutch switch hidden underneath the pedal and requires a two clip plug that i cant find anywhere in that area. I'll get a pic of it later.

Took this pic from Chris's build that thing you see there is the clutch switch

http://i3.photobucket.com/albums/y69/volumebikec0/IMG_1106.jpg

[biketsai]

Wait, WHA?! You found an actual sensor? My dumbass couldnt find anything, but I think I did find the harness that a sensor would attach to.

[AudiRacerS4]

Wait, WHA?! You found an actual sensor? My dumbass couldnt find anything, but I think I did find the harness that a sensor would attach to.

the pic above shows the clutch sensor switch, it has a two pin connector that looks identical to the one that plugs into the brake switch

[Jc61990]

yea where? i have a full pedal assembly too but it didnt come with a sensor on it. and when i search clutch switch online it comes up with that one that i moved.

http://cgi.ebay.com/ebaymotors/96-03-Audi-A4-A6-A8-VW-Brake-Clutch-Pedal-Switch_W0QQcmdZViewItemQQ_trksidZp3286Q2em20Q2el11 16QQhashZitem3ca0a5a32bQQitemZ260393247531QQptZMot orsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

the only thing i see is the master cyl and the clutch spring

also look at this all i see is the brake switch

http://tullinconcepts.com/ebaypictures/2000silveraudi89k/1/CIMG3130.JPG

[biketsai]

I might go take a peak under there later today, if I have that piece, then I know where the connector is too!

[Jc61990]

http://i3.photobucket.com/albums/y69/volumebikec0/IMG_1113.jpg

another pic from chris' thread where i dont see the switch.

[Jc61990]

okay so my friend came over, we were gonna start on the transmission, but he only had like an hour to help me so, we decided to go for the driveshaft,

we took the exhaust off , took off the heat shield. and started with the rear ds bolts. took a while we couldnt get them out, i texted chris he said to tap it with a hammer, still couldnt get them out then he called me and told me to try and use wd40 and beat the ds, that worked, i got 4 of the 6 on the rear out, the other 2 stripped. im gonna get new bolts from the hardware store, well that took us like 2 hours so we stopped lol.

but i figure if we get atleast the rear ds bolts off i can drop the trans with the front connected and bring it out as a whole. well now i know i need 2 more jack stands, and i need to wait for my tripple square sockets get here before i attack the transmission.


but other than that.. carnage shot.

not as bad as i thought. i think im gonna bring the pan to a machine shop and get it welded. then just sell the a/t trans as is

http://i27.photobucket.com/albums/c166/jc61990/IMG_0473.jpg

[AudiRacerS4]

yea where? i have a full pedal assembly too but it didnt come with a sensor on it. and when i search clutch switch online it comes up with that one that i moved.

http://cgi.ebay.com/ebaymotors/96-03-Audi-A4-A6-A8-VW-Brake-Clutch-Pedal-Switch_W0QQcmdZViewItemQQ_trksidZp3286Q2em20Q2el11 16QQhashZitem3ca0a5a32bQQitemZ260393247531QQptZMot orsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

the only thing i see is the master cyl and the clutch spring

also look at this all i see is the brake switch

http://tullinconcepts.com/ebaypictures/2000silveraudi89k/1/CIMG3130.JPG

ahh i hate to tell you this JC but you bought the wrong pedal assembly...you got the one for DBW cars, thats why yours is different

[Jc61990]

Nope that's an s4 pedal assembly. I got mine installed already. Bought a 96 2.8 pedal assembly. That pic is just a refrence

[AudiRacerS4]

Nope that's an s4 pedal assembly. I got mine installed already. Bought a 96 2.8 pedal assembly. That pic is just a refrence

oh ok just making sure, would have sucked to install it and then find out it was the wrong one

[Jc61990]

Yea... So just curious how much oil does the transmission take? Cause the shop that quoted me 800 to fix the a/t pan said 300 for a pan. 75 for the gasket and 37 for 1 qt of oil and it needs 9qts I found that hard to believe cause I bought 4 qts of redline oil and only spent 9$ a qt.

[biketsai]

Yea... So just curious how much oil does the transmission take? Cause the shop that quoted me 800 to fix the a/t pan said 300 for a pan. 75 for the gasket and 37 for 1 qt of oil and it needs 9qts I found that hard to believe cause I bought 4 qts of redline oil and only spent 9$ a qt.

Audi's ATF fluid is MONEY, Last time I bought a small thing of it it was like $27. Maybe 7-8 qts? (Just an estimate).

ATF is way more expensive compared to Redline etc

[PZ.]

9qts total. About 6qts with a pan and filter drop.

[Jc61990]

9qts total. About 6qts with a pan and filter drop.

A/t or m/t?

[biketsai]

A/t or m/t?

A/T

[biketsai]

ahh i hate to tell you this JC but you bought the wrong pedal assembly...you got the one for DBW cars, thats why yours is different

Wouldnt really matter much anyways since he could just use the clutch and brake pedals

[Jc61990]

what about the M/T about how much total fluid does it need

[biketsai]

what about the M/T about how much total fluid does it need

About 2.8 Quarts IIRC, I think I wrote it in my writeup. Fill the transmission up with 1/4 bottle of the shockproof. If you have the transmission level, the fluid will overflow once it is full.

[Jc61990]

havnt been here in a while. time for an update. well lets just say things were going good till about 2 weeks ago when everything went bad to worse..

started off on a friday with my gf wanting a break. ruined my weekend. we got back together saturday night. sunday morning, tried to take off the driveshaft and failed. only had an hour or so to try was busy that day. monday i had work and was with my gf. tuesday, gf wants break again. back into depression i went. we didnt speak till saturday when she told me she wanted to see me sunday afternoon. got there and we broke up. monday she calls me to come see her, i go over and we talked all night. tuesday morning we talked for like 5 min, then ignored all day, today ignored all day we had plans to go hangout as friends and she told me she was busy. friday we had made plans in advance and now i think she might back out of that. she wanted to be my friend still so idk. just been having bad week. and to make it worse. parents are basically telling me that i need to sell my car or get out. so i have to ditch this project. im pissed beyond belif. my auto trans pan is getting sent out to be weleded. the car is going back together, and im gonna drive it till i can sell it, then they are making me buy something that is less expensive to fix. and they told me no euro. so No VW. Audi. BMW. and w.e im just really mad. idk, this isnt the end of audi for me. im gonna get what i can cause they say i am in a finiancal hole and cant support myself so i need to get rid of the money pit.

soooooo

im selling everything.

Carbon Fiber 5 Speed Drive shaft
5 Speed Shifter box with JHM Linkage upgrade and short throw shifter
5 Speed Shifter knob and boot
00/01 A4 5 Speed Shifter trim also fits 00-02 S4. Black plastic
CLutch Pedal,
Clutch Master Cylinder
Manual Brake Pedal.
DBC Gas Pedal
pedal assembly. (will sell as a whole)


pm me for prices.

i am not happy about all this and belive me if i could afford moving out, i would, but i cant so i need to sell my car, or my parents WILL kick me out.

[grillhands]

havnt been here in a while. time for an update. well lets just say things were going good till about 2 weeks ago when everything went bad to worse..

started off on a friday with my gf wanting a break. ruined my weekend. we got back together saturday night. sunday morning, tried to take off the driveshaft and failed. only had an hour or so to try was busy that day. monday i had work and was with my gf. tuesday, gf wants break again. back into depression i went. we didnt speak till saturday when she told me she wanted to see me sunday afternoon. got there and we broke up. monday she calls me to come see her, i go over and we talked all night. tuesday morning we talked for like 5 min, then ignored all day, today ignored all day we had plans to go hangout as friends and she told me she was busy. friday we had made plans in advance and now i think she might back out of that. she wanted to be my friend still so idk. just been having bad week. and to make it worse. parents are basically telling me that i need to sell my car or get out. so i have to ditch this project. im pissed beyond belif. my auto trans pan is getting sent out to be weleded. the car is going back together, and im gonna drive it till i can sell it, then they are making me buy something that is less expensive to fix. and they told me no euro. so No VW. Audi. BMW. and w.e im just really mad. idk, this isnt the end of audi for me. im gonna get what i can cause they say i am in a finiancal hole and cant support myself so i need to get rid of the money pit.

soooooo

im selling everything.

Carbon Fiber 5 Speed Drive shaft
5 Speed Shifter box with JHM Linkage upgrade and short throw shifter
5 Speed Shifter knob and boot
00/01 A4 5 Speed Shifter trim also fits 00-02 S4. Black plastic
CLutch Pedal,
Clutch Master Cylinder
Manual Brake Pedal.
DBC Gas Pedal
pedal assembly. (will sell as a whole)


pm me for prices.

i am not happy about all this and belive me if i could afford moving out, i would, but i cant so i need to sell my car, or my parents WILL kick me out.

Bro that sucks so bad[=(] Now you're losing two girls in your life.

[Siena]

Sorry to hear this, Jc. I was really looking forward to your build.

Hopefully, things will look up soon, and you'll be back in the Euro saddle once more.

[biketsai]

whaaaaaaaaaaat?! Sorry to hear man, parents can suck at times.

[Jc61990]

Yea they suck soo much. They want me to get the pan welded drive it till I sell it. Then use what I make to buy another car... So basiclly they are telling me to get a 4k car. I'm soo pissed it's not even funny I asked them if I could get a 10k car put 4 down and finance the rest but they say I don't make enough to finance 6000$....... I have 2 jobs I make close to 400 a week. I can easily make my insurance. Phone. Car and my other payments a month. That's 1600 a month. And right now I only pay 300 a month for phone, insurance and I'm paying off an ATV my dad decided to buy me and make me pay off... I have zero credit so my parents would have to co sign a loan. Which of they did I'm sure my payments wouldn't be outrageous. For 6k. I can see what like 200 a month maybe. Idk I told them if I sell I want a WRX. I've wanted one before the audi and while I had it. So idk maybe I can get them to let me get it... But don't worry this isn't the end of audi for me. Once I land a nice job and can afford upkeep. Then hello B5 S4 :)

[biketsai]

Yea they suck soo much. They want me to get the pan welded drive it till I sell it. Then use what I make to buy another car... So basiclly they are telling me to get a 4k car. I'm soo pissed it's not even funny I asked them if I could get a 10k car put 4 down and finance the rest but they say I don't make enough to finance 6000$....... I have 2 jobs I make close to 400 a week. I can easily make my insurance. Phone. Car and my other payments a month. That's 1600 a month. And right now I only pay 300 a month for phone, insurance and I'm paying off an ATV my dad decided to buy me and make me pay off... I have zero credit so my parents would have to co sign a loan. Which of they did I'm sure my payments wouldn't be outrageous. For 6k. I can see what like 200 a month maybe. Idk I told them if I sell I want a WRX. I've wanted one before the audi and while I had it. So idk maybe I can get them to let me get it... But don't worry this isn't the end of audi for me. Once I land a nice job and can afford upkeep. Then hello B5 S4 :)

All of this makes no sense in the end [headbang]. Im sure with the amount of money you are making right now you can afford a badass ride, so I don't see why they don't let you finish the swap. Maybe you should just sell the A4 and buy another A4. Parents will be parents.

[Jc61990]

Not allowed to get another euro.. x_x