Another B5 A4 Manual swap.

[BruceT91]

Hey everyone. I'm going to do a basic walk-through of an engine/manual transmission swap for my girl's B5 A4 AEB 1.8t

BIG THANKS TO BIKETSAI for all the info in his thread!!:http://www.audizine.com/forum/showth...ual-Conversion

Her previous car, an '06 A3 with the 3.2 was totalled a few months back...16 year old texting wasn't paying attention and rear ended her.
[IMG][/IMG]




We picked up this '97 A4 with unknown mileage (odometer is blank and no title in Vermont) with an AEB and a 5 speed auto. It drove alright for the $500 we paid. It leaked oil since day one, needed a lot of TLC.
Eventually the water pump failed and I decided it was time to use my rotted out winter beater as a donor car.






We pulled the engine and 5 speed manual from the donor car (wish I had step by step pics of this) I'll do a step by step when I pull the other engine and auto trans this weekend. Also pictured my newest winter beater. V6 Auto (for now) passat.







New parts you'll need for the manual transmission.
- Drivers side B5 passat 5 speed manual trans mount bracket (OEM 8D0-399-113-AG) $50
- Passenger side mount bracket from a manual car.
- You can reuse or buy new automatic transmission mounts.
- I purchased both engine mounts, trans mounts and a snub mount (Meyle)

- I recommend the JHM shift linkage stabilizer bushing. It comes with a new hex bolt to make shift linkage easier to install.

[walky_talky20]

What is your source on the Driver's side V6 5MT mount bracket?

[BruceT91]

What is your source on the Driver's side V6 5MT mount bracket?

new OEM, I work at Audi South Burlington. Cost me around $50

[BruceT91]

Been busy and hadn't made much progress. Spent last weekend getting some stuff done on the car.


Once the old engine and auto trans were pulled I noticed the subframe had a rust hole right next to the lower rear control arm. (Thanks Vermont) Ordered a used one from Iowa, got a steal on it for $130 Shipped.


Old engine and auto trans were dropped into the donor car to be hauled away. Pulled clutch master, hard line, vacuum line, clutch petal and slave cylinder also at this time. So helpful having a full parts car..



Cleaned the bay and removed old subframe, control arms, and struts. Ordered new front wheel bearings to press in while its all apart.




Subframe bolted to auto trans mounts with new drivers side transmission mount bracket then rolled it forward under the car.




Lowered the car down to the subrame, installed new subrame bolts..now the car has a much more fresh AEB with the 5 speed manual.
Finally some progress!

[BruceT91]

While I'm posting a bunch of pictures, figured i'd share my own ongoing project. 2012 GTI with stage II Unitronic tune and some bolt ons. It stays off the road in the winter, trying to get it painted for spring along with some other upgrades.


Mostly waiting on parts now. FCP Euro front control arm kit, H&R springs, and front wheel bearings.
Bilstein sport shocks arrived


Hopefully getting a few more things done over the weekend. Cluster and pedal install most likely. Maybe suspension if parts arrive on time.

[zandrew]

Oh how I wish you were closer... I just bought an 01 avant and the hg is kaput. I am using it as an excuse to upgrade though...

Nice setup you have. A lil jealous. Best of luck but it looks like you got a grip on it.

Is the gti a dsg? If so how do you like it?

[BruceT91]

Oh how I wish you were closer... I just bought an 01 avant and the hg is kaput. I am using it as an excuse to upgrade though...

Nice setup you have. A lil jealous. Best of luck but it looks like you got a grip on it.

Is the gti a dsg? If so how do you like it?

Thanks, it's coming along well just not enough time in the week. The GTI is a 6-speed manual, but my good friend has a CC that is DSG. It's KO4'd with a DSG tune and it rips. DSG is a different animal once it's tuned. If you can afford the DSG service ever 40k or do it yourself it's a lot of fun and well worth it.

[BruceT91]

This weekend I was able to install the clutch pedal, clutch slave cylinder, clutch line, manual shift box, linkage, JHM bushing, and the drive shaft. Getting there..

JHM bushing - Much stiffer, you can really feel the improvement in the shifter.


Clutch pedal, brake pedal, and shift box installed


Clutch slave cylinder to clutch master cylinder hard line. You can see the routing well in this picture

[down_n_dapper]

nice work man! having just completed this swap, I know how much of a pain the pedals and little things are to swap but you're pretty much there!