General Notes
- Get the Bentley manual. Read it, there’s plenty of great information on transmission removal/installation.
- Reference Biketsai's write-up: http://www.audizine.com/forum/showth...ual-Conversion or http://www.audizine.com/forum/showth...ap-in-progress
- You can use parts from any B6- sedan, avant, or cabriolet.
- The TipTronic trans is HUGE. The difference in size between it and the 0A3 is astounding. Removing the TipTronic is a pain because of its size (follow the Bentley!).
- The size of the TipTronic is the reason for the difference in downpipes- the TipTronic downpipe is pushed farther to the passenger side. Of course, this interferes with the 0A3 transmission crossmember so you’ll need to rework your downpipe or get one from a manual transmissioned car.
- You can remove front CV halfshafts without removing any suspension members (at least for the 1.8T...).
- You could add the clutch pedal and smaller brake pedal to the auto trans pedal bracket, the bracket is the same.
- The pedal bracket is held in place by 2 bolts through the brake master cylinder/booster and 1 bolt up into the dash.
- You don't need to remove the brake master cylinder/booster in order to run the clutch line, it just takes some wiggling.
- the B5 method of using a 43mm bearing in the middle of the flywheel as a pilot bearing works, though its ability to stay in place will depend on your flywheel material. The steel FW with my FX700 was a touch over 43mm, I tack welded the bearing in place. Or you can get a 2.8 (probably 3.0 as well...) pilot bearing and trim it down to fit after removing the torque convertor bushing. Details here: http://www.audizine.com/forum/showth...=1#post6362409
Module Recoding
3 modules need to be recoded from auto to manual: ECU, ABS and cluster. You cannot recode a module when it has a fault, therefore it would be best to recode BEFORE removing the transmission and TCU. At a minimum, you need the TCU and the gear selector switch installed. You'll need to recode the ABS module first, as it seems to find fault with everyone else, then the ECU, then the cluster. With no recoding, the ABS/ESP lights are on and non-functional, ECU and cluster throw codes for the missing TCU. With cluster and ECU recoded, the ABS module gets more angry and flashes the brake light. You can recode the cluster at any time. Without recoding the ECU, any wheel speed above 0 it sets idle to ~1300 or so. Without the clutch switch, a recoded ECU will not have cruise control.
- To recode ABS for the manual transmission, use the information on Ross Tech's site. Use the appropriate login code for your DESIRED coding (i.e. login as if it were a manual transmission), change the coding of the module and perform the steering angle sensor calibration. Here's the text from Ross Tech's site should they ever go down:
Login
Note #1: After Login has been carried out you need to recode the control module.
Note #2: Special Login 07499 is used for 6-Cylinder Diesel Engine with 1LG Brakes and Multitronic.
Note #3: The Production Codes (PR-Code) such as 1LX can be found on a Sticker near the Spare Tire Well and/or the 1st Page of the Service Manual. Click here to see an Example of a Sticker.
0?xxx: Chassis
9 = Audi A4
0x?xx: Brakes
2 = Brembo 17" (PR-1LJ)
3 = FN3 16" (PR-1LT/1LF)
4 = HP2 16" (PR-1LX)
4 = FNR 16" (PR-1LA/1LG)
5 = FN3 15" (PR-1LB/1LE)
6 = C54 (PR-1LZ)
0xx?x: Engine
5 = 4/6 Cyl. Diesel
7 = 4/5 Cyl. Gasoline
9 = 6/8 Cyl. Gasoline
0xxx?: Transmission
5 = Manual
7 = Automatic (5HP19, 5HP24, AG4, AG5)
9 = Multitronic (01J, CVT)
Coding
Note #1: Coding is accepted after a specific login has been carried out.
Note #2: After successful coding the steering angle sensor basic setting needs to be carried out.
Note #3: Special Coding 04499 is used for BFB Engine with 1LT Brakes and Multitronic.
Note #4: The Production Codes (PR-Code) such as 1LX can be found on a Sticker near the Spare Tire Well and/or the 1st Page of the Service Manual. Click here to see an Example of a Sticker.
Note #5: In some cases, you will need to enter a non-zero WorkShop Code, such as 12345.
0?xxx: Chassis
4 = Audi A4
0x?xx: Brakes
1 = C54 (PR-1LZ)
2 = FN3 15" (PR-1LB/1LE)
3 = HP2 16" (PR-1LX)
3 = FNR 16" (PR-1LA/1LG)
4 = FN3 16" (PR-1LT/1LF)
5 = Brembo 17" (PR-1LJ)
0xx?x: Engine
5 = 4/6 Cyl. Diesel
7 = 4/5 Cyl. Gasoline
9 = 6/8 Cyl. Gasoline
0xxx?: Transmission
5 = Manual
7 = Automatic (5HP19, 5HP24, AG4, AG5)
9 = Multitronic (01J, CVT)
Basic Setting
Steering Angle Sensor (G85) Calibration
Before starting the procedure turn the steering wheel at least 30 ° left and back straight ahead.
[Meas. Blocks - 08]
Group 005 Field 1 (Steering Angle Sensor -G85-)
Specification: 0.0 °
Tolerance (when straight): ±5.0 °
[Done, Go Back]
[Login - 11]
Enter 40168
[Do It!]
[Basic Settings - 04]
Group 001
[Go!]
[Done, Go Back]
[Fault Codes - 02]
All fault codes should have disappeared.
[Done, Go Back]
- To recode cluster for the manual transmission, within VCDS goto adaptation channel 60, subtract 2 from whatever value you have there.
- To recode the ECU for the manual transmission, change the coding to 16701. You may need to login (I didn't have to), use 11463.
01 - Engine
Coding - 07
00XXX - The first two digits apply to the country.
*16 is the only available option for those in the USA
XX0XX - The third digit codes the ECU for what drive and options you have
*0 states FWD with ABS
*2 states Quattro with ABS
*5 states FWD with Anti-Slip Regulation/Electronic Stability Program (ASR/ESP)
*7 states Quattro with ESP
XXX0X - The fourth digit states which transmission you are equipped with
*0 is for 5 speed manual transmission
*5 is for 01V automatic transmission
XXXX0 - The last digit will state which vehicle the ECU is installed in.
*1 states installed in Audi A4
TipTronic Shifter Neutral Start Switch Defeat
- The transmission control unit (TCU, TCM) is located under the ECU in the driver cowl area (under the wipers)
- Under the transmission control module is the relay that must be removed and jumpered to allow the car to start (the "proper" name of the relay escapes me right now...).
Reverse Lights
The reverse lights need to be wired from the switch on the manual trans to pins 7 and 8 on the TipTronic multifunction switch wiring harness. walky_talky20 has a great write-up for the B5 here: http://www.audizine.com/forum/showth...a-5-speed-swap
Multifunction switch with reverse lights wired in:
Wiring connections to the switch are dependent on the transmission you use, the 0A3 transmission I used has a two pin connector for the reverse light switch:
Clutch Switch
You will want to wire up a clutch switch, without it you will be testing your rev limiter should you disengage your clutch while cruise is on as well as have an RPM jump on fast shifting and not having cruise control with the ECU properly coded. The B6 uses two switches on the clutch, the one that is needed to fix the previously listed problems is part number: 8E0 927 189B and resides next to the brake switch. walky_talky20 has a great write-up for the B5 (but it all applies to the B6 as well) here it is: http://www.audizine.com/forum/showth...Swap-%28DBW%29 What you’re doing is adding a wire to pin 39 on the ECU, running that wire to one terminal of the clutch switch and running the other terminal of the clutch switch to a tap off the black/brown wire of the brake pedal switch. Yes, pix with hands in them suck.
Pin 39:
Disassembling the ECU connector:
Pin 39 removed:
Wire added to pin 39:
ECU connector reassembled:
Pin 39 wire run to clutch switch, clutch switch tapped into brake switch:
Parts needed to complete the swap:
- brake/clutch pedals
- clutch master cyl
- clutch slave cyl (get an early B5 one, they're metal. The plastic one out of my donor '05 S4 was crumbling...it had 62k on it.)
- brake master cylinder reservoir to clutch master cylinder hose (6” of rubber fuel line would be fine)
- clutch slave cyl hard/soft line (get a braided stainless steel soft line, makes install easier)
- manual transmission (any B5, B6 or B7 manual transmission will bolt up)
- manual transmission crossmember or side mounts (must match whatever manual transmission you used)
- manual transmission front CV halfshafts (must match whatever manual transmission you used)
- clutch fork (must match whatever manual transmission you used)
- throw out bearing
- shifter assembly/control rods
- flywheel/clutch disc/pressure plate
- 43mm bearing for use as a pilot bearing (or the 3.0 pilot bearing, cut to fit)
- rear differential that matches final drive of the manual transmission you're using
- front to rear driveshaft (must match whatever manual transmission you used)
- manual transmission downpipe (or modify yours, substantial modification required)
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Originally Posted by walky_talky20
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