Biketsai's DIY Auto-to-Manual Conversion

[mike-2ptzero]

so what do u mean your peggin at 80? it wont go faster?

I think he just means thats his rpms at 80 mph in 5th gear which is slightly high for a 2.8 manual.

[Jc61990]

I think he just means thats his rpms at 80 mph in 5th gear which is slightly high for a 2.8 manual.

so then what did he mean when he said

Just swapped the rear end today so im not pegging it at 80mph!

[biketsai]

Sorry, I need to reword that. It felt like my RPM's were a lot higher, as if there was a lot more load on the engine. But in the end, the RPM's were the same with both rear ends. Tim, I am using the rear diff from the car I got the transmission from, 2000.

[aaronamerica]

i wonder how much time it would knock off my 1/8 or1/4 time at the track with the auto rear end, because the auto rear end defenitly accelerated alot faster in your car

[mike-2ptzero]

i wonder how much time it would knock off my 1/8 or1/4 time at the track with the auto rear end, because the auto rear end defenitly accelerated alot faster in your car

If you want to do that you might want to think about changing the transmission to a 01A that has a 4.11 front diff. I plan on testing one soon after we have the parts cryo treated. It has slightly shorter gearing which should help me at the drags.

[aaronamerica]

If you want to do that you might want to think about changing the transmission to a 01A that has a 4.11 front diff. I plan on testing one soon after we have the parts cryo treated. It has slightly shorter gearing which should help me at the drags.

what year tranny is that or whats the tranny code

[biketsai]

Just wanted to give everyone an update: The car is doing fantastic and Im pretty sure the clutch has broken in. The car feels great although I had one concern. If I am going WOT through the gears, if I push in the clutch pedal super fast before I shift the RPM's just 2-300. Is that because the car is rolling at an increasing speed?

Chris

[Jc61990]

Hey. Question. I'm getting my car back today once I get it I'm gonna start rippig into it and drop the trans. Once I get everything I don't need out I'm gonna put the shifter box in. Now do the linkage arms point towards the engine or towards the trunck? I don't have the trans yet to look at as a refrence so that's why I ask.

[zrowcool]

linkage arms from the shifter or from the trans?

[Jc61990]

Off the shifter box

[zrowcool]

towards engine,

[biketsai]

X2, I would recommend getting your pedal assembly/clutch master cylinder, and hydraulic lines put in asap, that should knock some time off when you get your transmission.

Edit: Hey JC, please spend the extra $40 for the JHM linkage piece. It will make installation of the linkage 100 times easier and will make things better too.

[Jc61990]

X2, I would recommend getting your pedal assembly/clutch master cylinder, and hydraulic lines put in asap, that should knock some time off when you get your transmission.

Edit: Hey JC, please spend the extra $40 for the JHM linkage piece. It will make installation of the linkage 100 times easier and will make things better too.

the pedals are in, the clutch master cyl is in, i need to find a parts car to get the hydraulic lines and i need to make a stop at autozone to buy the brake fluid line for the master cyl.

also, lets say i were to get a crankshaft from a 1.8t quattro manual and swapped it out with my current. would that fix the pilot bearing issue and not have to grind the crank down?

[biketsai]

the pedals are in, the clutch master cyl is in, i need to find a parts car to get the hydraulic lines and i need to make a stop at autozone to buy the brake fluid line for the master cyl.

also, lets say i were to get a crankshaft from a 1.8t quattro manual and swapped it out with my current. would that fix the pilot bearing issue and not have to grind the crank down?

Yes I believe that would fix the issue, but why not make it easy on yourself and resolve that issue with 5 minutes of slow grinding? If I had to swap the crank, I probably would not have done the swap.

[Jc61990]

The crank is only like 300$, but I see your reasoning I don't want to dig deep into my engine unless I had to. I'm gonna grind it down and get the pilot bearing. I'm peony gonna order 2 or 3 bearings incase I ever need to change the clutch in the future, I'll be set.. I contacted rai about the rest of the parts I need they are gonna get back to me with a price as a whole. My sister is letting me borrow her car for 2 weeks while she is getting surgery, and my grandma is lending me her car also after that so I will atleast have some sort of transprtation to work and w.e. I should be able to afford all this in like 4 weeks. I only make like 370 a week and I need to put gas in the loaner cars and have some money to live. I'm probly gonna put away 300 a week to save. I should have all the parts by the end of the month if all goes well. And while I'm savoy and my car is sitting I'm gonna be pulling the trans I'm going to grind the crank and change everything I need to and do as much as possible so when the time comes it will be a few hrs to just pop in the trans. I'm gonna try to recode my ecu. And did u ever re do the clutster? I don't hve an LCD I have the 2 strips. Prnd234 and the temp. If I pull the tcu will the top one just not do anything? I'll have to look into it. I have full vag-com so I'll play around. Can't wait to finially do this. It's been a thought in my head since I brought the car home last year.

[Jc61990]

So when u grind the crank what did u have on it besides the spacers? Was that all u grinded down to the spacer? Then put the fw on?

[Jc61990]

Hey Chris. I got somthing I want u to test. I was looking at te clutch switch online and it looks like the 2nd switch on the brake pedal, if u still have the relay. Plug it back in and move the Black switch I think it's the upper one on the brake pedal, move it to the clutch and try starting the car without steping on the clutch and then again with steping on it. I'm curious to see if I even need to buy the switch, cause I want it hooked up, I know my parents will move my car when they need too and I will always leave it
in gear.

[biketsai]

So when u grind the crank what did u have on it besides the spacers? Was that all u grinded down to the spacer? Then put the fw on?

Correct, spacers only. I had up to 3 on at one point and then pulled one out as I got closer. I just tried to keep it as even as possible. But you gotta remember there has to be at least some (2mm) of room for the flywheel to sit balanced on the crank. I'll check out the clutch switch online tonight.

[AudiRacerS4]

im interested in this clutch switch idea too

[Jc61990]

where did u find the jhm linkage for 40$ jhmotorsports.com wants 90$

[biketsai]

where did u find the jhm linkage for 40$ jhmotorsports.com wants 90$

My bad, it's actually just the bushing/bolt kit they have for $40

[Jc61990]

so just this?

http://www.jhmotorsports.com/shop/ca...products_id=29

[AudiRacerS4]

so just this?

http://www.jhmotorsports.com/shop/ca...products_id=29

yeah thats it

[Jc61990]

so i couldnt find a CV Bolt kit but i did notice in one of your pics u said there were 6 tripple square bolts on the axles, so i ordered this

http://www.ecstuning.com/Audi-B5_A4-..._Tools/ES9013/

i think i got just about everything now.

[biketsai]

so i couldnt find a CV Bolt kit but i did notice in one of your pics u said there were 6 tripple square bolts on the axles, so i ordered this

http://www.ecstuning.com/Audi-B5_A4-..._Tools/ES9013/

i think i got just about everything now.

Exactly what you need.

[robertjame]

Yo I just followed this walk through to do my own A4 and I'm at the end and am stuck, I have a 1997 1.8T FWD and have no park relay in spot #13. Nothing is there in fact. I was wondering if that was something that they added later of if its in all models. Plus I was wondering if it was the same a the starter relay, as in are they one and the same park/starter. The car wont turn over, I hear a relay start clicking when I turn the key but not sure witch one it is. Also wondering if my starter died in the middle of the build. I'm really hammered on this one, solid week of work on this can and I'm at a wall over a little relay. Any help would be great.

[biketsai]

Yo I just followed this walk through to do my own A4 and I'm at the end and am stuck, I have a 1997 1.8T FWD and have no park relay in spot #13. Nothing is there in fact. I was wondering if that was something that they added later of if its in all models. Plus I was wondering if it was the same a the starter relay, as in are they one and the same park/starter. The car wont turn over, I hear a relay start clicking when I turn the key but not sure witch one it is. Also wondering if my starter died in the middle of the build. I'm really hammered on this one, solid week of work on this can and I'm at a wall over a little relay. Any help would be great.

Although there is no relay there, do you see any electrical connector behind it in that area? Take a picture of it if you can, PM me for my # if you need some extra help.

Edit: just realized you live in Raleigh! I lived there this summer right off Harrison, too bad im not there or else I could have helped you out.

[robertjame]

I worked at the Bonefish grill on Harrison last year. I live by NC State now. But no there is no outlet installed in spot 13. I have spent almost the same amount of time messing with the wiring as I did on the whole build. lol My car is out in my friends shop 30 min from me, when I get out there tomorrow Ill take a picture. Will the park relay keep it from firering the starter? Thanks for responding.

[biketsai]

I'm assuming you hve tried to start it already? I'll make a phone call tomorrow and see if werewolves might be able to give some insight.

[robertjame]

I sure have tried to start it, I hear a clicking noise of a relay or solenoid but no crank out of the starter. No power at all. Ill take a pic of the relay box tomorrow night and send it to you. Plus I'm going to pull the starter tomorrow night and bench test it. Then if it works, test the hot wires to the starter. But The relay thing has had me on my head for days. Do you think I could push start it? Thanks for looking in to it for me.

Rob

[biketsai]

I sure have tried to start it, I hear a clicking noise of a relay or solenoid but no crank out of the starter. No power at all. Ill take a pic of the relay box tomorrow night and send it to you. Plus I'm going to pull the starter tomorrow night and bench test it. Then if it works, test the hot wires to the starter. But The relay thing has had me on my head for days. Do you think I could push start it? Thanks for looking in to it for me.

Rob

Usually you should hear a clicking noise when you turn the key on. If I were you I would just try starting the car using a thick piece of wire and manually powering the starter, I did this to rule out my starter being the issue. I think you could push start it however thats wierd that you do not have anything in that spot.

[werewolves182]

Usually you should hear a clicking noise when you turn the key on. If I were you I would just try starting the car using a thick piece of wire and manually powering the starter, I did this to rule out my starter being the issue. I think you could push start it however thats wierd that you do not have anything in that spot.

Robertjame, do this before anything else. This will pretty much narrow down your issue to the relay needing to be jumped. You don't really have to use a thick wire either, I used a 16awg wire. Just attach one end to the spade connector on your starter and tap the other end to the positive battery terminal and it should start right up. Its just a 12v signal wire.

I'm looking now for where your park relay is located on your 97 FWD.

[robertjame]

Yeah that's what I just did, it starts right up, my clutch grabs, shifter is all there, everything is good just cant key start it. I took pictures of my relay panel, Ill up load them in like and hour, I'm filthy. BTW you guys are great for all the help your write up has giving me plus all the tec support, couldn't have done it with out you guys.

[biketsai]

Good to hear, just gotta find that relay position now. Do you happen to see any relays with the number 53 on it?

[robertjame]

opps forgot to put a memory card in my cam lol. no pictures till tomorrow. No #53 relay. There are two relays behind the relay panel, 213 and 214, I unpluged 213 and is shot an auto trans relay code fault in the ecm. but no start. I put it back. but my relay box looks just like yours with out anything in #13.

[werewolves182]

Do you have any relays in the box that houses your ECU?

[robertjame]

I don't believe so but if I said I knew for sure Id be lying. I believe there is the a sensor for air pressure, the ecu, the harness major ends and then all the minor ends. I will take pics tomorrow of everything I can see and get them to you. Plus I had another question, what did you guys do for the sensor in the manual trans, just leave it unpluged? isn't that what turns the reveres lights on?

The 2 relays I mentioned before are right under the ecu in the dash, like right under it, like I said before one of them was deff for the auto trans, but Im not sure what the other was for. #213 and #214, grouped in with a bunch of heavy fuses.

[biketsai]

I believe I have only 1 or 2 plugs in and its for the speed sensor. I currently do not have reverse lights, or cruise control.

[robertjame]

Thats what I figured, no biggie. I know you can change the harness for it buts its like imposable to find.

[werewolves182]

Here ya go man. This is where your park relay is. Remove the circles relay and jump the 2 pins circled in my crude MSpaint drawing.

EDIT: To answer your question about the 2nd sensor on the trans. Like Chris said, the sensor right next the the driver side hub is for the VSS, the other sensor is for the reverse lights. I have yet to be able to to find the right wires to connect to the reverse light sensor. Im currently running with no reverse lights, no biggie, just have to ride the brakes a little when reversing so I can behind me at night.