B5 A4 01E Swap Info Thread

[catbed]

Having just completed this swap, I found it very difficult to find all of the information necessary to complete it. There were many posts I found simply listing all of the parts related to the drivetrain, and others needed only a few of them. There are many parts needed to complete the swap, available from many different cars, and depending on which route you take and the year of your car it can be completed fairly easily. I figured I would make a thread where we can organize all of the information in one place to help anyone doing the swap later on.


Some background: My car is a BAT 01 A4 Avant with an AWM 1.8t that is making close to 400AWHP. I saw full boost (25psi) at ~4800 RPM with the 01A. The reason I swapped a 6MT into my car is I had already blown up 2 5MT and wanted a transmission I could drive without worrying about breaking. So I used an 01E out of a 01.5 B5S4. I bought the trans used with 100k miles with the linkage and mounts for $800, which is a fairly low price. Most 01Es that don't require an immediate rebuild are around $1000, but you can score ones needing a 1-2 syncro or shift collar for around $4-500. The 1-2 syncros breaking and shift collars are common problems on 01Es.


First things first, is this transmission suitable for a 1.8L 4 cylinder engine?

This is the most asked question I have noticed when researching the swap. Having driven both now, around town and on the highway, I feel I can shed some light on the subject It isn't the ideal transmission, simply because it was meant for an engine that produced more torque than our 1.8Ts can, ie the 2.7t. Because of this, 1-3 gears are slightly taller, and 4-5 are slightly shorter. HERE (http://www.audizine.com/forum/showthread.php/401119-Discussion-Gear-Ratio-for-01E-amp-01A) is a thread that discussed the gearing of various transmissions, both 5- and 6-Speed.

The gearing is not really noticeable in first gear, but I did notice a slight difference when driving around town in 2-3. It is not bad to drive at all, and with the shorter 4.11 final drive vs. the 3.89 of the 5 speed, it really doesn't struggle to accelerate at all around town. On the highway, it drives pretty much the same, but there is more shifting necessary to keep it in the powerband, but that is with any BAT car really. At 85mph, the engine is turning at 3500 RPM, a drop of about 500 RPM from the 4k RPM with the 01A. I did notice an increase in gas mileage on my 252 mile trip to school, averaging about 22 MPG with 630cc injectors and tune. That was not all just cruising either, as I did multiple pulls and a tunnel blast.[evilsmile]


Now that you've decided you want to get rid of your 5MT and swap in the much stronger 6MT, you'll need to gather your necessary parts. Depending on what year your car is dictates what parts you will need, and there are several options to take. There are several differences between the 5MT and the 6MT that need to be addressed before the swap can be completed. The option that I took is the easiest and the cheapest, IMO.

I'll break it down into the problems that you will face during the swap, and solutions to them depending on which car you are swapping into. The first thing to consider is:

Mounts


If you drive a V6 A4, then you will be able to utilize the stock 01E mounts, since you share the same subframe as the S4.
If you own a 1.8T A4, then you run into the problem of their subframe using a different style mount on the drivers side. To solve this problem, you can either:
make your own bracket for the stock 1.8t mount
cut the 1.8t mount off the subframe and weld in the V6 bracket
swap subframes



Since my car is a 1.8T, I had to do something about my drivers side mount. I chose to make my own bracket for the mount since I had an 034 Street Density mount there already.


Axles

The S4 uses a 108mm inner axle flange rather than the 100mm flange that the A4s use. To make this work, you can:


Swap 100mm flanges into the 01E, but the ones from the 01A do not fit. Where can you find 100mm flanges that will fit into the 01E? The stock rear diff. They bolt into the diff using a hex head bolt, just like the 01E. So remove the screws, swap the flanges, and put the bolts back in. MAKE SURE YOU KEEP THE BOLTS WITH THE FLANGES. The 01E flange bolts will not work with the A4 diff cups.

Swap in the front axles from an S4. To do this, different parts are needed depending on the year of the car.

96-00 A4 1.8t

S4 Axles
S4 Uprights & Hubs
S4 ABS Sensor


01 1.8T & 96-01 V6

S4 Front axles


Since the 01 1.8T and V6 A4s all have the same larger outer CV Joint as the S4, no uprights are needed to swap in S4 axles.



Rear Diff

Because the final drive of the 01E is different than the 01A, the rear diff has to be changed. There are two differentials that will work, both have the code DAK:


S4 Rear Diff

Direct bolt in, requires use of S4 rear axles or swapping of the diff flanges
Tiptronic A4 Diff

Direct bolt in, uses stock A4 axles


Driveshaft

The 01E is a few inches longer than the 01A, so a shorter driveshaft is needed. There are not many ways around this, you either have to use a S4 unit, or a aftermarket 1-piece unit made for the B5S4.

Shifter

The 01E shift rods can be used with any shift box in the car, but the 5MT shift boxes will NOT have a reverse lockout. The H-pattern isn't exactly nice, since I think the pivot ball on the 6MT shift boxes is moved slightly to the left.

Other Issues

I started a different thread asking whether or not I would have clearance issues with my CM FX400 240mm clutch/FW combo. The answer is there is no clearance issues and the cranks spins without issue when the transmission is bolted down.

EDIT: I found out this is not actually true. My fx400 disc was rattling, so I pulled the trans after about 5k miles. The CM flywheel/fx400 combo rubs the bellhousing ever so gently. Not enough to make a terrible noise, but enough for there to be marks before it self clearances. I have included a pic below. I simply removed slightly more material using a die grinder. Re-installed everything and haven't had a problem since.

http://img.tapatalk.com/d/13/02/26/3y2a7yqy.jpg

http://img.tapatalk.com/d/13/02/26/9ytybapu.jpg



The route I chose consisted of swapping the trans, driveshaft, and diff. The diff I got from an automatic A4 so everything else is stock A4. Because of this, I was able to complete the swap for just $1100.

Trans - $800
Driveshaft - $100
DAK Rear Diff - $200


I am currently using my 01A shifter but plan on swapping in a 6MT very soon, and they are very inexpensive.

That's pretty much it for now, if I come across any relevant pictures I'll edit this post and add them in. I have a few pictures of my swap, but I just need to get them off my camera. If anyone has any info to add, post it up and I can either add it to the first post, or at least it will be in the same thread if someone is searching.

[lorge1989]

http://www.audizine.com/forum/showthread.php/401119-Discussion-Gear-Ratio-for-01E-amp-01A

Lots of info there. And it is a well know issue that the O1E has absolutely terrible ratios when compared to the O1A for any motor that has a decent size turbo. When doing this swap the question is not if the ratios are okay, but is the sacrifice worth it. That is, is the durability of the O1E worth the sacrifice of gear ratios. Most of the time the answer is yes if you go through all the trouble.

[Meow]

Get a taller 6th gear while you are doing it, its fucking awesome on the highway.

[catbed]

http://www.audizine.com/forum/showthread.php/401119-Discussion-Gear-Ratio-for-01E-amp-01A

Lots of info there. And it is a well know issue that the O1E has absolutely terrible ratios when compared to the O1A for any motor that has a decent size turbo. When doing this swap the question is not if the ratios are okay, but is the sacrifice worth it. That is, is the durability of the O1E worth the sacrifice of gear ratios. Most of the time the answer is yes if you go through all the trouble.

Thanks for the link, I'll add it to the post.


Get a taller 6th gear while you are doing it, its fucking awesome on the highway.

So I have heard. My friend is planning on doing that in his S4 when the time comes to rebuild.


Added info to first post, and formatting.

[redline380]

i havent researched the 01e swap much (not really interested), but nice to have this info in one place. i really thought the swap couldnt be done for less than $2000, unless a donor car was had for less. kudos

[Urtorsen]

FAQ....DIY ...STICKY!!! Please.....so we can have this in the future.

[Vierings]

Get a taller 6th gear while you are doing it, its fucking awesome on the highway.

Just a thought here, I know it would be labor intensive, but couldn't you swap 1-5 gear of the 5 speed to the 6? And then get a taller 6th? Or since people seem to like the rs4 3rd gear have the gears be 1,2,4,5 from the a4. 3 from the rs4 and 6th as a tall gear?

[spindoctor]

Good info!


Vote for a sticky/FAQ!

[lorge1989]

No you can't. 1st and 2nd are part of the input shaft. I don't believe its possible, or it is but its not possible from a financial standpoint. The biggest issue with any of the 01Es is the 1-2 shift. 3rd and 4th are tall but manageable. If you ever get into 5th and 6th and need to know how fast they will take you there is a good chance you are going way too fast.

On that note I don't think I'd ever get a longer 6th gear with a 1.8T. It might be cool for a 2.7, but it would bog and bog and bog if you ever had to pass at a speed under 80.

[Urtorsen]

Just a thought here, I know it would be labor intensive, but couldn't you swap 1-5 gear of the 5 speed to the 6? And then get a taller 6th? Or since people seem to like the rs4 3rd gear have the gears be 1,2,4,5 from the a4. 3 from the rs4 and 6th as a tall gear?
maybe the input and output shafts are different on each

[un1ko]

Good info!

[Gberg888]

Great info, was thinking about the swap... maybe in the future.

[Gberg888]

needed to subscribe sorry guys

[derekb727]

Is there any wiring that needs to be done?

I was under the impression that you needed to wire in a connector from an S4 harness into the A4 harness.


Thanks!!

[nynoah]

I just wish there was a trans with the same gear ratios but one more for 6th. I drove down to NM from Denver and was cruising at 80+ and I would really like to save the gas. Out west there are many stretches of road where cruising well over 80 is possible. I even ramped it up to 140 for a sec.

[catbed]

Is there any wiring that needs to be done?

I was under the impression that you needed to wire in a connector from an S4 harness into the A4 harness.


Thanks!!

The only thing that is different wiring wise is the reverse light. 01A uses a 5-pin and the 01E uses a 2-pin.


I just wish there was a trans with the same gear ratios but one more for 6th. I drove down to NM from Denver and was cruising at 80+ and I would really like to save the gas. Out west there are many stretches of road where cruising well over 80 is possible. I even ramped it up to 140 for a sec.

The B6 A4 3.0 USP 01E has slightly friendlier ratios for a 1.8t.



EDIT: Added info about CM/fx400 clutch combo.

[nynoah]

Yeah but what does it take to put that trans into my 01 1.8T?

[derekb727]

The only thing that is different wiring wise is the reverse light. 01A uses a 5-pin and the 01E uses a 2-pin.





So the speed sensor has the same clip and you will use the sensor for the trans. So 01E sensor stays in, you do not have to swap speed sensors?

For the reverse light you need to wire in the correct clip in order for it to work?

Thanks

[catbed]

Yeah but what does it take to put that trans into my 01 1.8T?

Same process as this thread. [:)]


So the speed sensor has the same clip and you will use the sensor for the trans. So 01E sensor stays in, you do not have to swap speed sensors?

For the reverse light you need to wire in the correct clip in order for it to work?

Thanks

Speed sensor is the same, it stays in the trans. No need to touch the connector for that either.

For the reverse lights, you just need to clip the old wires and solder in about 12" of wire with the 2-pin connector. You can use any 2-pin connector i.e. N75, fuel injectors, etc.

[derekb727]

Is there polarity or can i just connect either wire?

Thanks for the help

[catbed]

Is there polarity or can i just connect either wire?

Thanks for the help

Just a switch, so doesn't matter the polarity.

[b518]

Nice was looking for this

Sent from my SPH-D710 using Tapatalk 2

[GOODBYNAAIR]

Nice would love to do this later on, driving my GFs 3.0 6speed is a dream on the high way.

[Nollywood]

Get a taller 6th gear while you are doing it, its fucking awesome on the highway.

I did just that - but I replaced 4th, 5th and 6th with gears from a 2004 C5 Allroad 2,5 TDI. I feel replacing just 6th (depending upon the source, and how tall) will create quite an rpm drop when shifting from 5th to 6th.

[derekb727]

Okay, last question.

On the 01E trans that I have there is a sensor that it towards the top that came from the donor car. it is close to the edge of the bell housing and looks to go over the flywheel.

Can anyone tell me what it is and if I need to use it?

If I remember correctly there was no sensor there for the 01A

[Haenszel20v]

Okay, last question.

On the 01E trans that I have there is a sensor that it towards the top that came from the donor car. it is close to the edge of the bell housing and looks to go over the flywheel.

Can anyone tell me what it is and if I need to use it?

If I remember correctly there was no sensor there for the 01A

That's the crank sensor on the S4. You do not need it.

[derekb727]

Trying to do the install right now.
I read everything I think.
Do you use the spacer or not?

The one that goes between the engine and trans?

[nynoah]

Spacer is for the 2.7

[lepermessiah]

Hi guys,

I came here few months ago when I was searching for some hints for swapping my old 01A transmission to 01E. Well, nothing is perfect and that's why I need to ask for your help :/

Reasons for transmission swap were:
1. my old 01A wasn't in her best condition - when breaking with engine, after shifting from 4 to 3 and 3 to 2 whole car was wincing
2. I'm driving 60% out of city with average speed 70-90mph, so tall 6th gear was really good reason

After swapping (my mechanic did it) transmission and putting new Valeo 228mm clutch in, I had big problems with starting engine and shifting. When I started engine, clutch (I think it was clutch) was making scratchy sounds and it stopped after few minutes. I couldn't change gears without turning off engine because when I pressed clutch pedal, nothing happend. When the car was towed with engine runinng and without gear, after 2 miles there was terrible smell from clutch (RPM on cluster were at 900). After asking catbed throught my friend I swapped clutch slave cylinder and problems with shifting are gone. Scratchy sounds are gone too, but I think it's because that something just got chipped of from transmission body or clutch plate.
Now I can start without problems, shift without problems, but clutch still smells as it's slipping and I can't go faster than 20mph.

Here is video of my problem, you can see it best between 2nd and 10th second (RPM vs speed). Does anyone know what's wrong with it? My mechanic says that clutch is mounted OK, clutch fork too, slave cylinder too... :/ He doesn't know what to try and he also doesn't have time to investigate that problem... when I was asking about clutch plate setup (as I saw something on YT from ZF for proper setup of plate) he told me, that there is no setup needed for clutch in B5


http://www.youtube.com/watch?v=ocQfSzjkUsI

[A4Rob]

Did he bleed it?

[lepermessiah]

of course he did :/ clutch pedal is working normally as before, only clutch is slipping

[catbed]

So it sounds like the clutch is not engaging fully. What TOB did you use?

Which clutch/flywheel did you use?

[lepermessiah]

hmm I don't understand what "TOB" is :/

flywheel is stock from my 1.8T AEB, it was in perfect condition. Clutch set is Valeo 228mm (I will switch to Stage3 later so I just wanted something in normal price)

EDIT: so I've searched for TOB :) .. it's used from Valeo set

EDIT2: I've asked mechanic about clutch set. He doesn't know what brand of flywheel is there (but it's the one from factory - 162k miles on stock clutch, not bad :) ) and whole clutch set (clutch, clutch pressure plate, release bearing) is Valeo 228mm set. He told me, that he mounted over 200 clutches and the problem that my clutch is not working is because there is that 01E transmission and so it won't work. I wonder why everybody else here doesn't have such problems ..

PS: I read somewhere on net that Valeo release bearing is little bit thicker than Sachs/LUK and that Sachs pressure plate won't fit on LUK flywheel, so I hope that I don't have LUK flywheel

[catbed]

hmm I don't understand what "TOB" is :/

flywheel is stock from my 1.8T AEB, it was in perfect condition. Clutch set is Valeo 228mm (I will switch to Stage3 later so I just wanted something in normal price)

EDIT: so I've searched for TOB :) .. it's used from Valeo set

EDIT2: I've asked mechanic about clutch set. He doesn't know what brand of flywheel is there (but it's the one from factory - 162k miles on stock clutch, not bad :) ) and whole clutch set (clutch, clutch pressure plate, release bearing) is Valeo 228mm set. He told me, that he mounted over 200 clutches and the problem that my clutch is not working is because there is that 01E transmission and so it won't work. I wonder why everybody else here doesn't have such problems ..

PS: I read somewhere on net that Valeo release bearing is little bit thicker than Sachs/LUK and that Sachs pressure plate won't fit on LUK flywheel, so I hope that I don't have LUK flywheel

I'm not so sure the AEB flywheel will play nicely with the 01E, especially a stock flywheel. And I know that some TOBs are longer than others, as you have said. I believe the problems lies in the flywheel and TOB.

[lepermessiah]

well, let's give that Valeo set a chance, what flywheel will you recommend then ? I don't want super lightweight flywheel because I'm not using car for racing or so .. I'm planning to have GTRS mounted before winter, so I don't know what to get. the problem is that 1.8T has 6 bolts but 2.7 has 8 bolts, so S4 flywheel won't fit :/

[Nollywood]

TOB is the same for 01A and 01E. Sounds like the clutch is too far from the TOB / lever. This can occur if the flywheel is too thin, giving a combined clutch stack height of less than 83mm.

Was the spacer plate used?

[catbed]

TOB is the same for 01A and 01E. Sounds like the clutch is too far from the TOB / lever. This can occur if the flywheel is too thin, giving a combined clutch stack height of less than 83mm.

Was the spacer plate used?

You have it backwards. The TOB is pressing against the fingers causing the clutch to be disengaged slightly, causing slip.



well, let's give that Valeo set a chance, what flywheel will you recommend then ? I don't want super lightweight flywheel because I'm not using car for racing or so .. I'm planning to have GTRS mounted before winter, so I don't know what to get. the problem is that 1.8T has 6 bolts but 2.7 has 8 bolts, so S4 flywheel won't fit :/

ECS has the RA flywheel, or you could just get a SMFW. My ClutchMasters SMFW weighs 19lbs.

S4 flywheel is too thick for the 1.8t block anyway.

[viceprp]

Catbed,
Did you happen to look into rebuilding the 01A transmission? And if you did, what was the that cost vs. the 01E swap?

[lepermessiah]

@catbed I see that clutchmasters have dealer in our region, so I will try to ask him, but can you tell me which flywheel ? I'm lost on their page, I like their FX-250 kit but it's without flywheel. I don't know if I should go for 240mm or 228mm flywheel (or is it the same?)

ECS is only in US so it would cost +40% to deliver and pay duties etc.

[spindoctor]

^^ suggest contact mike@ringer racing for flywheel and clutch deals. I just placed an order for a 240mm FX350 clutch kit with a 2500lbs PP. I already have a Spec 16lbs 240mm flywheel.

[lepermessiah]

@Nollywood no spacer was not used, as it's not compatible with 1.8T block

@spindoctor I will try to get flywheel somewhere from Europe and if I have no luck, I will try to get something from US :/

but if I understand it right, I can't put 228mm clutch on 240mm flywheel, so I think that I need to look for thinner 228mm flywheel or thinner release bearing. I don't have money to buy whole 240mm kit for $1000 or more

EDIT: looks like ALL clutch sets for B5 have same release bearing, but there are 2 different release forks, so I will try to look for number of my fork and if it's the taller one, I will order the other and if it doesn't help, I will order RA4 (my stock flywheel is single mass)

INFO: ClutchMasters kit (for max. 420Nm/310PS as I requested) with lightweight flywheel costs 1440€ in EU (over $1900 USD !!) through official dealer - that's too much, still hoping for that release fork

[Iapetos]

Good Info!

[lepermessiah]

so I've ordered RA4 flywheel with RS4 clutch kit, I hope that it will work

my 228mm clutch looks little bit burnt but pressure plate is totally dead - after 5 miles :D

[lepermessiah]

OK guys, problem solved. RA4 with RS4 clutch works good, but I need to rework exhaust as it's too thick (2.75 pipe) and has no room beside the gearbox so it's making weird noise and whole car vibrates

[Crispy222]

one problem solved, another shows up.

[chris164935]

So, if I'm reading this correctly, the stock-sized clutch/flywheel setup from a 1.8t will not work with an 01E? My current set up is a Clutchmasters FX725 twin-disc with steel flywheel.

[lepermessiah]

yes, stock flywheel is too thick for this swap. it's at least 2 times thicker than custom RA4 flywheel

[M-Hood]

yes, stock flywheel is too thick for this swap. it's at least 2 times thicker than custom RA4 flywheel

It is thinner because it is designed to be used with a 240mm LUK pressure plate which is way taller then the stock Sach pressure plate.



So, if I'm reading this correctly, the stock-sized clutch/flywheel setup from a 1.8t will not work with an 01E? My current set up is a Clutchmasters FX725 twin-disc with steel flywheel.

It will work as long as the stack height of the flywheel/pressure plate are not too tall, if it is too tall the top of the pressure plate will hit the back of the bell housing. You shouldn't have a problem with the FX725 fitting since the stack height is not even as tall as the stock clutch/flywheel, which is why it uses a taller TB. A CM 240mm clutch/flywheel will fit with the 01E which means a CM 228mm will also fit since it tends to be slightly shorter then the CM 240mm setup. Even the FX850 fits, Gunnar is running the FX850 twin with a 01E on his 1.8t.

[Schrubbe8210]

So just for clarification, as a guy who has literally all the supporting parts sitting in his garage, and is picking up the 01e this weekend, the stock 228mm clutch/flywheel/TOB setup will not work due to it being too thick. Neither will mix and matched sets of OEM/aftermarket parts. However, any complete aftermarket clutchmasters clutch/flywheel/TOB set (either 228 or 240mm) for a 1.8t will play nice with the 01e? All this back and forth with lepermessiah confused me.

[ricekikr]

What brakes are needed for a pre-facelift 1.8tqm?

Will i also need rear axles and uprights?

[Crispy222]

What brakes are needed for a pre-facelift 1.8tqm?

Will i also need rear axles and uprights?

If you're following this parts list:

96-00 A4 1.8t
S4 Axles
S4 Uprights & Hubs
S4 ABS Sensor

You would need S4 brakes or something aftermarket (Brembo/Stop Tech) with adaptors.

Rear axles:

S4 Rear Diff
Direct bolt in, requires use of S4 rear axles or swapping of the diff flanges
Tiptronic A4 Diff
Direct bolt in, uses stock A4 axles

[S4NIK8]

Anyone with a more "medium" (2860) size turbo do this swap? My 01A is on it's way out after 250k and I have an 01E sitting in my garage.

[redline380]

I really think the sweet spot for a medium sized turbo is a 5 cylinder 01e 5 speed, but I have no personal experience to back this thought up

[S4NIK8]

I really think the sweet spot for a medium sized turbo is a 5 cylinder 01e 5 speed, but I have no personal experience to back this thought up

Well I guess I'll find out; probably swap it in next week depending on my schedule.

[pee quu]

So just for clarification, as a guy who has literally all the supporting parts sitting in his garage, and is picking up the 01e this weekend, the stock 228mm clutch/flywheel/TOB setup will not work due to it being too thick. Neither will mix and matched sets of OEM/aftermarket parts. However, any complete aftermarket clutchmasters clutch/flywheel/TOB set (either 228 or 240mm) for a 1.8t will play nice with the 01e? All this back and forth with lepermessiah confused me.

My thoughts exactly!!! too much back and forth I have everything sitting in my garage ( trans, subframe, axles, driveshaft, rear diff, front uprights) I just want to know what else i Need and what clutch/ flywheel i need

[pee quu]

btw my 1.8t has a k04 , not my daily so really not overly concerned with all this mpg and gear rations. I just want to put this stuff to use since the trans was rebulit about 20k ago and is not going to the project I originaly got it for

[chris164935]

Can anyone shed some more light on the differences between the early style and late style 01E transmissions from the B5 S4s? I recently purchased an 01E but the seller does not remember which MY it came from. I plan on purchasing all of JHM's shifter stuff, so, basically, would I just need these:
Gear Shift Lever Base (http://www.ecstuning.com/Audi-B5_S4--2.7T/Drivetrain/Shifter/ES2522951/)
Selector Rod Clamp (http://www.ecstuning.com/Audi-B5_S4--2.7T/Drivetrain/Shifter/ES424974/)
And the 2 shifter rods? Also, I'm guessing that if I used the above parts, I would need the late model JHM stuff?
The car itself is a 2001 A4 5-speed 1.8t.

[M-Hood]

Can anyone shed some more light on the differences between the early style and late style 01E transmissions from the B5 S4s? I recently purchased an 01E but the seller does not remember which MY it came from. I plan on purchasing all of JHM's shifter stuff, so, basically, would I just need these:
Gear Shift Lever Base (http://www.ecstuning.com/Audi-B5_S4--2.7T/Drivetrain/Shifter/ES2522951/)
Selector Rod Clamp (http://www.ecstuning.com/Audi-B5_S4--2.7T/Drivetrain/Shifter/ES424974/)
And the 2 shifter rods? Also, I'm guessing that if I used the above parts, I would need the late model JHM stuff?
The car itself is a 2001 A4 5-speed 1.8t.



Pretty sure when it comes to which JHM shifter you need to order it depends on which base you are going to be using in the car.

This is stated on the JHM web site.

If you have a pre 2000 S4/A6/Allroad or a pre 1999.5 A4 and your shifter looks like this (metal base) please do the following.



-For Early pre 2000 S4/A6/Allroad - select the "OEM Base for Pre 2000 non-US:" option at the bottom of the order page for STS-B5S4E.

- For Early Pre 1999.5 A4 w pushdown reverse - you must order the STS-B5A4E shifter that upgrades you to NON push down reverse like the newer 99.5 up A4.



Doing so will upgrade you to the newer version and upgraded plastic base thus allowing you to put a JHM "solid" short throw shifter in your car.

Notice the base is metal (old style) instead of plastic (new style).


http://jhmotorsports.com/products/shifterstyle/B5_A4-S4_97-99.5_shifter_Assy.JPG


So it should be the late shifter you need if you are getting the plastic OEM S4 base.

[S4NIK8]

To add to this, there are no clearance issues with a spec stage 3 228mm clutch and awe flywheel. Haven't driven the car much since finishing the swap so no real impressions on the gearing differences.

[catbed]

Pretty sure when it comes to which JHM shifter you need to order it depends on which base you are going to be using in the car.

This is stated on the JHM web site.



So it should be the late shifter you need if you are getting the plastic OEM S4 base.

The cross rod on the trans is also different.

http://tullinconcepts.com/ebaypictures/07222010/IMG_1132.JPG

[ricekikr]

For the reverse lights, you just need to clip the old wires and solder in about 12" of wire with the 2-pin connector. You can use any 2-pin connector i.e. N75, fuel injectors, etc.

Are there different kinds of reverse switches? Mine looks like it has round corners. No way will an n75/injector plug fit.

[ricekikr]

Just finshed my swap.

A4 abs sensor works just fine. No codes. Just spaced it out using a thick washer.

A4 neuspeed shifter works but without reverse lockout. Guessing game if in reverse or first. It is centered. 01e shifter box + a4 neuspeed.

[demonmk2]

I wonder if anyone on the board has used the jhm carbon synchro kit
and how well it holds up to the added power.

[GoremanX]

Confused about why the S4 uprights are required at all... on my 2001 A4 1.8T, the wheel hub end of the front axles are identical between A4 and S4. Both 100mm and 108mm axles will fit in either of those wheel hubs. And track width is close enough as makes no real difference as far as axle length is concerned. I'm currently swapping in an 01E and purchased the S4 uprights based on the info in this thread, only to find that I didn't need them.

I understand the need for 108mm vs 100mm axles (since the transmission output hubs are different), but I don't get why the uprights need to change.

[ricekikr]

Confused about why the S4 uprights are required at all... on my 2001 A4 1.8T, the wheel hub end of the front axles are identical between A4 and S4. Both 100mm and 108mm axles will fit in either of those wheel hubs. And track width is close enough as makes no real difference as far as axle length is concerned. I'm currently swapping in an 01E and purchased the S4 uprights based on the info in this thread, only to find that I didn't need them.

I understand the need for 108mm vs 100mm axles (since the transmission output hubs are different), but I don't get why the uprights need to change.

The a4 1.8t quattro m/t have smaller hub bearings than the s4. There are some a4 models (forget which) that have the same hub bearing size as the s4.

[GoremanX]

The a4 1.8t quattro m/t have smaller hub bearings than the s4. There are some a4 models (forget which) that have the same hub bearing size as the s4.

Must be mine then, because my 2001 A4 with AWM 1.8T m/t has the exact same bearings as the ones in the S4 uprights I purchased.

Pretty handy, means I don't have to waste money buying S4 calipers. Kinda wish I hadn't wasted the money on the uprights, though...

[Bordom]

Confused about why the S4 uprights are required at all... on my 2001 A4 1.8T, the wheel hub end of the front axles are identical between A4 and S4. Both 100mm and 108mm axles will fit in either of those wheel hubs. And track width is close enough as makes no real difference as far as axle length is concerned. I'm currently swapping in an 01E and purchased the S4 uprights based on the info in this thread, only to find that I didn't need them.

I understand the need for 108mm vs 100mm axles (since the transmission output hubs are different), but I don't get why the uprights need to change.


The a4 1.8t quattro m/t have smaller hub bearings than the s4. There are some a4 models (forget which) that have the same hub bearing size as the s4.
01 A4 1.8T got the B5 V6 82mm wheel bearings as standard.

Must be mine then, because my 2001 A4 with AWM 1.8T m/t has the exact same bearings as the ones in the S4 uprights I purchased.

Pretty handy, means I don't have to waste money buying S4 calipers. Kinda wish I hadn't wasted the money on the uprights, though...
You cannot use S4 front brakes on A4 uprights as the caliper mounting ears are too close together, hence necessitating S4 uprights

Everything graciously mispelled by Android

[GoremanX]

01 A4 1.8T got the B5 V6 82mm wheel bearings as standard.

You cannot use S4 front brakes on A4 uprights as the caliper mounting ears are too close together, hence necessitating S4 uprights


err, yeah. I know. That's what I said. "I don't need to buy S4 calipers because I'm not going to use the S4 uprights that I bought for nothing" (paraphrased). This means I can re-use my A4 uprights and keep my existing A4 calipers, A8 brackets and A8 312mm slotted rotors. Money saved. *cha ching!*

edit: in fact, wouldn't that be the ideal thing for anyone to do? Acquire the A4 V6 or A4 AWM uprights if those aren't already on the car? I bet there's a ton more of those available to buy than S4 uprights, and possibly for less money. That way there's never any need to spend money on S4 brakes at all when converting to a 6-speed. Also, could retain the existing ABS sensors. They wouldn't even need to come out. Even more money saved. Probably no alignment needed afterward either. Yet MORE money saved!

*cha ching!* *cha ching!* *cha ching!*

[M-Hood]

Don't really have to do any of that stuff, don't even have to buy new front axles since you can just swap the flanges off the rear diff and put them on the 01E to use your stock A4 01A front axles.

[ray4624]

so that that point, you would just need transmission, driveshaft and rear dif?

[M-Hood]

so that that point, you would just need transmission, driveshaft and rear dif?

Plus the shifter box, S4 6 speed shifter and linkages. Then there is dealing with the transmission brackets/mounts, I used a custom bracket to mount the 01E to my stock 1.8t manual sub frame on the driver side and the stock 01E passenger side transmission bracket. Other option for the 1.8t owners is to switch to the other subframe which is used in the 2.8/2.8 and 1.8t Auto.

[ray4624]

i remember seeing that bracket. It looked like something i could have fabbed up. Easier then swapping subframes.
I more or less dont want to swap uprights and lose my bbk etc.

Dont know if its worth it at all. When i inevitably blow apart my 01a maybe ill just source another used one.

[GoremanX]

Plus the shifter box, S4 6 speed shifter and linkages.

Wait... shifter box? I can't re-use my 01A shifter box with an 01E?

[PZ.]

I used the stock clutch setup without issues on my swap. I swapped from a V6/Tip combo to the 1.8T/01E on my 01 B5. I will need to upgrade the clutch as I have more traction than clutch and even a 2k launch results in slippage. I've got a RS4 PP and Kevlar clutch sitting in the garage from when I picked up the trans, but I don't know if I want to go 240mm on the flywheel of keep the stock 228.

[nynoah]

Must be mine then, because my 2001 A4 with AWM 1.8T m/t has the exact same bearings as the ones in the S4 uprights I purchased.

Pretty handy, means I don't have to waste money buying S4 calipers. Kinda wish I hadn't wasted the money on the uprights, though...

This is not true. The S4 uprights have different brake caliper mounting points. The AWM uprights just use a larger bearing but still have the smaller A4 brake mounting points.

[GoremanX]

Plus the shifter box...

This is incorrect. The shifter box is the same between 01A and 01E. Even the bellows for the rods works fine. The shifter base needs changing. but not the box.

[M-Hood]

This is incorrect. The shifter box is the same between 01A and 01E. Even the bellows for the rods works fine. The shifter base needs changing. but not the box.

When I say box I meant the actual base.

[GoremanX]

When does the reverse light switch actually close? When the shifter is moved all the way to the left (past the 1/2 gate), or when the shifter is physically engaged into reverse? My reverse lights aren't working, and so far I've narrowed it down to the reverse switch itself. I'm wondering if maybe I don't have the shifter adjusted properly so it isn't pushing the rod far enough to close the switch.

[GOODBYNAAIR]

I used the stock clutch setup without issues on my swap. I swapped from a V6/Tip combo to the 1.8T/01E on my 01 B5. I will need to upgrade the clutch as I have more traction than clutch and even a 2k launch results in slippage. I've got a RS4 PP and Kevlar clutch sitting in the garage from when I picked up the trans, but I don't know if I want to go 240mm on the flywheel of keep the stock 228.
If you plan on making power later on go 240mm and save yourself some headache later on. That being said the 228mm can hold it down with the right clutch but for the most part the price on any decant clutch and fw setup will not be much different 228 vs 240. I have a 240mm 6 puck not great for DD but makes for a fun weekend worrier.

Sent from my SM-T560NU using Tapatalk

[freekonwheelz1]

to bring back a somewhat dead thread, who all has done a b6 a4 1.8t 6 speed swap into a b5 a4? is it worth it or are there more hoops to jump through than doing an 01e trans? i am building a holset powered 1.8t and my end power goal is going to be higher than my 01a will like (at least i hope i make too much power for it) and after reading and reading i am curious as to why that 6 speed is less prefered to the 01e... [confused] its made for a 1.8t and has a final drive similar to what our cars already have. but i have never seen how they are mounted or what electronics it might have that ours dont. if anyone has any info on why i should do the 01e swap instead of the b6 6 speed i would greatly appreciate it!

[Rodgman15]

to bring back a somewhat dead thread, who all has done a b6 a4 1.8t 6 speed swap into a b5 a4? is it worth it or are there more hoops to jump through than doing an 01e trans? i am building a holset powered 1.8t and my end power goal is going to be higher than my 01a will like (at least i hope i make too much power for it) and after reading and reading i am curious as to why that 6 speed is less prefered to the 01e... [confused] its made for a 1.8t and has a final drive similar to what our cars already have. but i have never seen how they are mounted or what electronics it might have that ours dont. if anyone has any info on why i should do the 01e swap instead of the b6 6 speed i would greatly appreciate it!
Mike Hood has done it. Needed custom mounts fabricated, he may have extras, look him up. Don't quote me,I may be misremembering.

[Crispy222]

Mike Hood has done it. Needed custom mounts fabricated, he may have extras, look him up. Don't quote me,I may be misremembering.

No, Mike used a B6 3.0 01E 6spd. B6 1.8t 6spd is a 0A2 and is not as strong the 01E. It will need custom brackets as the B6 does not have side brackets. It uses a W-brace towards the middle of the trans.

[Rodgman15]

No, Mike used a B6 3.0 01E 6spd. B6 1.8t 6spd is a 0A2 and is not as strong the 01E. It will need custom brackets as the B6 does not have side brackets. It uses a W-brace towards the middle of the trans.
Thanks for clarifying lol. I knew I had at least one aspect goofed up.

[freekonwheelz1]

No, Mike used a B6 3.0 01E 6spd. B6 1.8t 6spd is a 0A2 and is not as strong the 01E. It will need custom brackets as the B6 does not have side brackets. It uses a W-brace towards the middle of the trans.

i figured it didnt handle as much power. oh well! never hurts to ask! well for me to 01e swap my b5 1.8t i would need a custom mount or a new subframe anyway where as the b6 i believe needs a custom mount but uses the 3.89 final drive, if i remember correctly so it would make for an easier swap, right..? or does the b6 3.0 01e still use a 4.11 final drive? im just trying to toss ideas around in my head for when i break this 01a. third gear already isnt happy so its gonna fail me sooner or later.

[M-Hood]

No, Mike used a B6 3.0 01E 6spd. B6 1.8t 6spd is a 0A2 and is not as strong the 01E. It will need custom brackets as the B6 does not have side brackets. It uses a W-brace towards the middle of the trans.

I used a combination of a B5 S4 01E and some gearing out of a B6 3.0 01E since the B6 01E transmission was pretty much toast once we opened it up. The B6 A4 1.8t is actually a 02X, same transmission that is in the B7 A4 1.8t, they aren't nearly as strong and the reason we can't use them in the B5 is because they use 1 lower transmission mount and a cradle to hold it in place.

I did use a custom bracket on the left side to hold my 01E directly to my B5 A4 1.8t subframe, I also had another mount bracket made to work with the stock style stand up mount but did not end up using that one on my car.


IIRC the 02A transmission is what comes in the B6/B7 4.2 cars.

[freekonwheelz1]

I used a combination of a B5 S4 01E and some gearing out of a B6 3.0 01E since the B6 01E transmission was pretty much toast once we opened it up. The B6 A4 1.8t is actually a 02X, same transmission that is in the B7 A4 1.8t, they aren't nearly as strong and the reason we can't use them in the B5 is because they use 1 lower transmission mount and a cradle to hold it in place.

I did use a custom bracket on the left side to hold my 01E directly to my B5 A4 1.8t subframe, I also had another mount bracket made to work with the stock style stand up mount but did not end up using that one on my car.


IIRC the 02A transmission is what comes in the B6/B7 4.2 cars.

makes sense. audi wouldnt of left us a good tranny to swap easily too lol but i will continue my search for an 01e i suppose. im in no rush anyway. the car doesnt even run and when it does run itll be low power until i get my AEB head built and my rods and pistons dropped in. hopefully this time next year ill be collecting parts to swap my tranny for. hopefully third gear holds up until then! [>_<]

[Mooseranch]

Old topic but hoping someone here can help. My son has a B6 1.8T FWD that we just swapped the AWD and 01E into from a 3.0 donor car. Everything is done but the starter does not want to engage. I didn't see any comments prior to completing the swap regarding starter problems and since the starter, flywheel and clutch are from the AMB engine, I didn't anticipate any problems. Starter bolts in fine but again seems to be hitting the flywheel teeth not allowing it to engage. The 3.0 starter is totally different due to spacer used on that combination. The starter hole in the thin 1.8T spacer/backing plate matches the transmission and the starter itself fits that as well. No issue bolting it up at all.

I don't see a difference in starter between for the 1.8's until later with a different solenoid clocking angle and connector for from the harness for the trigger wire. I have pulled the starter and bench tested it. The gear seems to through out normally and starter turns with vigor. Anyone else run into this problem.

[Mooseranch]

OK It looks like the bolt holes in the bell housing on the 01E are larger diameter than the 5spd and the bolt size for the starter itsself which allows the starter to move slightly in the opening. There is no way the 3.0 starter will work since the engine case is in the way of the mount hole for the lower bolt for the 3.0 starter. I re-installed the 1.8 starter and it worked but it is making a lot of noise so I believe it is too tight against the ring gear and whining as the gear disengages. I guess I'll have to sleeve the bolts in the bell housing to center the starter.

[Mooseranch]

It's back on the road as an AWD 6spd with no issues on it's first drive! A couple tweeks to the exhaust to clear the new rear carrier and the tail section of the 01E and installation of a resonator. Took of the Koni coilovers until we get something with less drop. Idaho is not friendly with that much drop. A few more tweeks and the kid should be happy for a while.

http://www.audizine.com/gallery/showphoto.php?photo=87340&title=b6-a4-k04-turbo-tt-injectors-2c-awd-6spd-conversion&cat=500

[OverSpun]

^ Good work!

Besides- This thread should be in the FAQ/Tech forum... I'll move this over. [:)]