I'm creating this thread, as some sort of resource, for those doing various transmission swaps, or even engine swaps with different transmission. So really, where different engines and manual gearboxes are mixed up, to produce the desired result.
Some cars have a spacer between the engine and gearbox, some don't. There are many who believe the function of this spacer, is to provide the desired distance from the clutch slave cylinder plunger, to the clutch pressure plate, via the throw-out bearing and fork. Or, to provide the required distance between the transmission shaft and the clutch friction disk.
Having done so many different transmission swaps, from the 016, 01A, 02X and 01E, I can tell you the spacer isn't really to do with the clutch slave cylinder plunger, or transmission shaft length. Since 1986, with the introduction of the 012 gearbox, the shaft has pretty much become a standard fitment, both in terms of spline count and thickness, to the protrusion from the gearbox.
Earlier gearboxes - 016 / 093 had a shorter shaft, with a smaller diameter and spline count. 012 and later, both 5 and 6 speed grew in length, girth and spline count.
The spacer (which I always toss) is to provide space for the clutch pressure plate, depending on the stack height when combined with an OEM or similar dual-mass flywheel. So, we're talking space within the clutch housing.
Generally, clutch / flywheel combinations with a stack height of approx. 86.0mm will fit within an 01A, 01E, 01X, 02X, 012, 0A2, 0A3 without the need of a spacer.
The 4 cylinder engines don't run that thick spacer, neither do the original Audi's with factory V8 motors, combined with a manual gearbox. These are as follows:
Audi V8 D11.
Audi S4 Plus C4.
Audi S6 Plus C4.
Audi S8 D2.
Audi's with V6 engines, that do require the spacer:
Audi S4 B5.
Audi RS4 B5.
Audi A4 B6 3.0 V6.
Audi A4 B7 3.2 V6.
Audi A6 C5 2.7T.
Audi A6 C5 3.0 V6.
Audi's with V8 engines, that do require the spacer:
Audi S4 B6.
Audi S4 B7.
Audi RS4 B7.
Spacer plate thicknesses:
Audi S4 B6/7: 5.5mm (01E 103 551 G).
Audi S4 B5: 11.2mm (01E 103 551 C).
Audi RS4 B5: 11.2mm (01E 103 551 C).
Audi A4 B6 3.0 V6: 11.2mm (01E 103 551 C).
Audi A4 B7 3.2 V6: 11.2mm (01X 103 551 A).
Audi A6 C5 3.0 V6: 11.2mm (01E 103 551 C).
Audi A6 C5 2.7T: 11.2mm (01E 103 551 C).
Audi RS4 B7: 5.5mm (01X 103 551).
Audi A6 C6 2.7 V6 TDI: 5.5mm (01X 103 551).
Audi A6 C6 3.0 V6 TDI: 5.5mm (01X 103 551).
Some 4 cylinder models had a shim of some sort, not truly a spacer, as some mechanics have left it out after a clutch job, and the car has not felt, or driven any differently. Typically, these are made out of pressed steel, though some are aluminium. Often about 1mm in thickness, or less. I won't list the cars they were fitted to, but I'll list their part numbers:
06B 103 551 G.
06B 103 551 K.
06B 103 551 L.
My findings are based upon personal experience, both as a privateer, and working with VAG (Audi, Volkswagen, Volkswagen Commercial and Seat) dealerships for a combined 23 years. I will continue to add to this resource, as I gather more information.
Moderators, if this could be stickied, that would be awesome. I typed this in a rush, using my phone at work, so my apologies if there are typographical errors, or the thread itself is in the wrong place.
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Originally Posted by Kevin C
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