09A to 02j EUH: BEW Manual Swap
Hi everyone, new member as of today. Got to p.66 before I decided to join, I guess this opened up the search thread option; which definitely helped me come to the conclusion that my question has not been answered yet. Who knows tho, sorry if it has. I quoted alphasenior and GdB to hopefully get their attention, they definitely seem to know what they're talking about. First off this thread is awesome, has helped me get my head around everything coming up, thanks to everyone. Just joined today, but have searched these forums a bunch and normally get solutions. This and YouTube, you can find a lot of stuff on YouTube these days.
I have an 04 Jetta TDI GLS with the BEW engine and the 09A Tiptronic 5spd automatic. This may get a little off topic, but I swear it comes back around. Recently, the 09A has started not wanting to go into reverse. This happens mostly after the car has been run and then parked, but can normally be overcome by turning the car off, restarting and then trying again, maybe a couple times before it works. Also, when driving at revs around a shift point, it sometimes seems not to know what it wants to do. I'm thinking solenoids, this transmission apparently has problems with this, plus I don't have problems under normal or heavy acceleration or with it slipping out of reverse once it's there. Other than that and a forever soft break pedal, I love this car. Just put a 1.5" drop h&r cup kit and front and rear sway bars on the car, as well as a bunch of Polyurethane bushings in the suspension, basically everything but the end link bushings, I'll get them later. Also, I was lucky enough to find a nice set of Audi Fat Fives local on Craigslist. She is beautiful and drives like a dream.
I bought the solenoid replacement kit and ATF and planned to change them out. Then, whats this. An 02J EUH shows up on Ebay, one of the MTs that comes factory on the BEW. The seller is parting out an 04 Golf TDI GLS BEW with collision damage. This guys a champ, he's pulling everything this week and I'm driving 5.5hs to pick this stuff up this weekend. He's giving me a good price on everything I've asked for and says it was in good condition before the accident. Has 184,000 on it.
When I got the car me and my father swapped the engine cause it was blowing smoke and loosing power. At the time we changed the ATF, filled it according the the Bently and had it checked on the local AAMCO's VAG-COM because the trans seemed a little weird at first, but they said we were spot on. It's been good till now. We've done a manual swap on a 91 Corolla before, but things were different back then. My father handled the electronics, I'm not that good, and this isn't his car. Still we got the engine swap done in 3 days and that includes having to re-separate the engine/trans because I forgot to tuck the metal dust pan behind the clip. Which caused the torque converter bolts to smack the pan during startup. I thought I'd destroyed my car when I heard it.
Thanks to this thread, I've come up with this shopping list:
Sourced from car:
Transmission
Clutch/Flywheel - I'll get a new one when this fails. He said it worked.
Both Dust Covers
Drive Axles
Linkage Cables and Sift Tower
Clutch Pedal and Hydraulics
Clutch Pedal Firewall Gasket
Manual Coolant Hoses
Manual Power Steering Line
Manual Trans Mount
ECU
Instrument Cluster
Wiring Harness (I told him if it has to be cut, as far back as possible would be preferable. If not the whole thing)
TCU? Based on what I've read here, I don't think the MT has a TCU.
All associated nuts, bolt, brackets, clips, connectors, etc, etc, etc.
Buying:
Axle Flange bolts and backing plates
Axle Nuts
Crush Washers for PS Line
Trans Mount Bolts
MTF
Shifter Alignment Pin
Axle Seals
Rear Main Seal- Do I need this Pookie stuff?
Input Shaft Seal
Turbo to Exhaust Nuts and Gasket
Flywheel Bolts
Throw out Bearing
Clutch Alignment Tool
This is my daily driver with no real backup besides getting a ride. I'm really hoping I can get this done in less than four days. Basically my questions are. Is there anything else I need? Is it Foolish to think that I would be able to chop my wiring harness and rewire it with the front half of this one? They're both BEW; I cant see them being extremely different. Do I need this relay 53 with a BEW? Is the VSS system going to work since I'm getting the Instrument Cluster and ECU? What about the Immobilizer? Should I have to even mess with a VAG-COM as long as wiring is correct?
Also, I still want to replace the solenoids in the 09A and get that working correctly. Will do this either way actually as I already have the parts and will still be driving it until I'm ready to start. I'm thinking if anyone on here wants to buy it instead of trying this swap, let me know. I'd basically have everything for an 09A conversion too, with new solenoids installed and a bunch of extra ATF, if you want to do that. If not, I'll try to resell it on EBay or Craigslist.
Any help would be appreciated, and thanks again for this site.
Yes, that should be your a27 bus
I should update this by removing the wire colors since they are not consistent. It only confuses.