03 Cabriolet 1.8 CVT to 5spd Swap in progress - questions

**f4i-pilot** · 03-28-2016 08:10 AM

I bought a complete 03 donor car to do my swap, and yes my CVT was toast. TCM replacment 5months ago $$$ and now Clutch pack fail.. I'm done with it

. The car is in very good condition with just over 101K.
Question is : I have not seen anybody do a swap to a Cabby, is there anything I should be on the lookout for or aware of.

List of what I have taken off the donor car or bought recently.
5 spd FPS FWD trans
Shifter assembly
full pedal set with switches
Axels
New trans mount - do it while it's out
New rear main - again do it while it's out
New Valeo Clutch, Pressure Plate and SMFW
Genuine VAGCOM Hex+Can
have the clutch hardline, but bought a USP for ease
Doing Motor Mounts and Snub mount for GP as well.

I actually have the ECU and Wiring harness from the donor, but I would rather just add the reverse light than replace the whole harness and VAGCOM the ECU from CVT to Manual..

As of last night I have removed:
Cat and exhaust
Oil Lines
Axels
Center console
Pedals
CVT Shifter
and I have 7 bolts cracked loose

**customa4** · 03-28-2016 08:35 AM

Let's get some pictures in here! Good luck with the swap, have the same planned for the near future.

**f4i-pilot** · 03-28-2016 10:01 AM

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**f4i-pilot** · 03-28-2016 10:04 AM

One thing I did a little different but saved me a ton of time and effort.
I did not completely remove the subframe, it is still attached to the lower control arms, but hanging 3-4 inches below. I had easy access to starter, and lower transmission bolts, seem to be easier for me.

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**f4i-pilot** · 03-28-2016 07:25 PM

Pig is OUT, all by myself

Well that was fun

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**walky_talky20** · 03-28-2016 08:00 PM

I approve of this thread. This is the good and proper solution to chronic MultiTronic issues.

Nice work so far!

**f4i-pilot** · 03-29-2016 08:33 AM

Originally Posted by walky_talky20

I approve of this thread. This is the good and proper solution to chronic MultiTronic issues.

Nice work so far!

ANy idea is there is any real difference between the crossmembers
I have the CVT 8E0399261Q
and Parts ID states that the 5spd uses 8E399261P, I havent taken the one off the donor car yet, but is it really different?

**k909068** · 03-29-2016 09:17 AM

Pretty good work there!

**customa4** · 03-29-2016 11:30 AM

Originally Posted by f4i-pilot

ANy idea is there is any real difference between the crossmembers
I have the CVT 8E0399261Q
and Parts ID states that the 5spd uses 8E399261P, I havent taken the one off the donor car yet, but is it really different?

Pretty sure both should work since the transmission mounts are the same between the 5 speed and CVT. I could be wrong though.

**f4i-pilot** · 03-31-2016 10:02 PM

Getting some progress in tonight
Got the coolant flange done, motor mounts in, rear main seal done, and mounted and torqued the flywheel

and a little transmission tunnel selphie

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**customa4** · 04-01-2016 05:57 AM

You need a pilot bearing. Guessing you have that already though, right?

**f4i-pilot** · 04-01-2016 06:18 AM

Yep I know, didn't realize it wasn't in the box. I'll have in today! USP didn't ship my SS clutch line so I kinda hosed on finishing it this weekend

Guess I'll just get the trans in and finish the interior, pedals and wiring.

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**customa4** · 04-01-2016 06:24 AM

Damn your quick. This thread gives me motivation to start mine. I have all of the parts and I was told I should grab USP's clutch line. I'll wait to get your opinion and maybe I'll just take that route. The last thing I need is any extra hiccups.

**f4i-pilot** · 04-01-2016 06:28 AM

I'll be able to give you some short cuts when I do my final write up, but my biggest issue was getting direct bolt on, no fabricating, no rigging.
And for me I've used virtually all OEM Audi parts. Little pricey but worth it to me.

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**customa4** · 04-01-2016 06:38 AM

Originally Posted by f4i-pilot

I'll be able to give you some short cuts when I do my final write up, but my biggest issue was getting direct bolt on, no fabricating, no rigging.
And for me I've used virtually all OEM Audi parts. Little pricey but worth it to me.

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Agree. I like to stick to OEM parts as well. Did the clutch job on my current B6 not too long ago and replaced just about everything with OEM parts. Pilot bearing, rear main seal, clutch fork, and all of the pivot parts on the transmission. Valeo clutch kit.

**f4i-pilot** · 04-03-2016 10:35 PM

Getting close, got a lot done this weekend
Clutch, transmission, shifter, center console, starter, axels, catalytic converter all back in
Tomorrow- hydraulic line, pedals, tie up subframe bolts and check everything for torque.
Bleed hydraulics, fill coolant, and start wiring( reverse, clutch engage/disengage) and coding still left to do

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**f4i-pilot** · 04-03-2016 10:36 PM

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**f4i-pilot** · 04-04-2016 11:48 PM

Well I'm a little screwed, transmission mount is an 1.5 in off
Dammit, back to the board
I have everything done, went to lift and tie in the subframe and nope

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**f4i-pilot** · 04-05-2016 06:37 AM

Need help quickly, does anyone have a crossmember from one of these cars
8E0366261P

Audi A4 Audi A4/Avant 2002 2003 2004 2005
Audi A4 Audi A4/Avant 2005 2006 2007 2008
Audi A4Q Audi A4/S4/Avant quattro 2002 2003 2004 2005
Audi A4Q Audi A4/S4/Avant quattro 2005 2006 2007 2008
Audi AA4C Audi A4/S4 Cabrio./qu. 2003 2004 2005 2006
Audi AA4C Audi A4/S4 Cabrio./qu. 2007 2008 2009

**customa4** · 04-05-2016 06:56 AM

So the subframe is fine but you need a different crossmember for under the transmission?

**f4i-pilot** · 04-05-2016 07:03 AM

Yep

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**customa4** · 04-05-2016 07:05 AM

That's disappointing to hear. Local junkyard, partout, craigslist, ebay maybe.

**f4i-pilot** · 04-05-2016 07:39 AM

Just sent out an APB on classifieds

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**Kevin C** · 04-05-2016 07:39 AM

Originally Posted by f4i-pilot

Pig is OUT, all by myself
Well that was fun

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I have been having the same fun... Good times. I got my 6 speed in on Saturday. I'm down to swapping in the rear diff ( 3.89 ratio vs 4.11).

Good work!!!

**f4i-pilot** · 04-05-2016 07:40 AM

Fortunately I'm only doing FWD

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**customa4** · 04-05-2016 07:56 AM

Anything other than the CVT is an upgrade.

Check car-part.com. I just searched on there and found quite a few. The part is under "transmission crossmember".

**f4i-pilot** · 04-05-2016 08:01 AM

Originally Posted by customa4

Anything other than the CVT is an upgrade.

Not if l can get it to move, I'm so pissed too. I was ready to bleed the system and start coding
Dammmmmmmm!

Added a Nav cause I thought I was ahead of the game, cost wise.
Everything to this point was free and I was up about $250.00

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**customa4** · 04-05-2016 08:03 AM

I updated my post above. I would just use a jack to get the transmission in place so you can continue.

**f4i-pilot** · 04-05-2016 08:43 AM

Oh I'm gonna finish, just now I have to wait on another damn part.

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**SJorge3442** · 04-05-2016 09:02 AM

Originally Posted by f4i-pilot

Oh I'm gonna finish, just now I have to wait on another damn part.

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yeah car-part.com is great as it scans local junk yards. Just don't try to email a junkyard.....they never respond. Pick up the phone and I bet you can have your hands on a cross member by 5pm.

**f4i-pilot** · 04-05-2016 09:08 AM

Closest one is in Jersey

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**customa4** · 04-05-2016 09:17 AM

Probably the best you're gonna get. Will they do shipping? Kinda sucks, might get expensive. Only other option most likely is to go to a local yard and hope for the best. If there's a B6 there I'm sure the crossmember is still available.

**walky_talky20** · 04-05-2016 09:17 AM

That might not be a piece they often catalog. I might try looking up the transmission it fits (manual trans B6). If they have the transmission, give them a call and see if they have the crossmember.

Another option would be to mount it like a Tiptronic (2 side mounts to subframe ears). Might be easier pieces to find.

**f4i-pilot** · 04-05-2016 09:29 AM

It's a FPS code transmission and the ETKA list I posted up was showing like 20cars that have the same crossmember, unless I'm reading it incorrectly

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**walky_talky20** · 04-05-2016 09:50 AM

I mean the junkyards. If you are looking on car-part, that crossmember piece may not be one the junkyards actually list as having available. They might not have interchange info for it, isn't a popular part, so isn't worth their time to worry about it. It's a nice piece of aluminum scrap. But if you find the junkyards that have the right car, you can call them up and see if they (1) still have the actual car, (2) could go look at it and see if the crossmember is present and in good condition, and (3) would agree to sell it to you for a reasonable sum.

The other option I described is to procure a B6 Tiptronic subframe (if your CVT subframe does not have the 'ears') - which is only the most common B6 subframe ever - and then get the B5 2.8 5MT mount brackets:

Left Bracket: https://www.ecstuning.com/Search/Sit...13AG/ES429710/
Right Bracket: https://www.ecstuning.com/Search/Sit...08_R/ES429708/

These brackets mount an 012/01A 5-speed manual trans on the same mounting points as a 5-speed Tiptronic box. Often used as an easy means to convert a tiptronic car to manual trans. There might be some gotcha with the B6 exhaust, if it's downpipe routing is significantly different than the B5. That might be something to check first.

**f4i-pilot** · 04-05-2016 07:14 PM

So we have found the issue, measured mine

And Larry Fopp, measured a damaged one and its 2&3/4
Bingo!
Now I need someone to sell me either 5spd FWD or 5spd Quattro crossmember

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**walky_talky20** · 04-06-2016 11:09 AM

Wait...I thought you had a donor car? I'm confused.

**f4i-pilot** · 04-06-2016 11:20 AM

I did and I screwed up reading the numbers on the crossmember
They both are
8E0399263, but ones an R and the others a SAB(CVT)
Audi made it interesting to figure out any differences
got a little confused on ETKA
I'll have it back tomorrow, I had already sold the shell of the donor.

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**f4i-pilot** · 04-07-2016 06:24 PM

So more of a clean up question
What did you guys do with the CVT harness
Just cut it or painstakingly remove pin by pin from the connector at the ECU?

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