Audi Allroad 2.7T 6spd =» 2.0TDI BHW + 2.5TDI 6spd Allroad gearbox

stp359 · Dec 11, 2015

Here it is!
The original car is a black 2005 2.7t Allroad 6spd manual. It will receive a 2.0TDI BHW engine from a 2005 Passat and a 6 spd transmission from a 2.5TDI Allroad from Europe.
http://pics.tdiclub.com/data/uploads//413482/DSC014231.JPG

the 2.7 is out
http://pics.tdiclub.com/data/uploads//413482/DSC01434.JPG

This is the fastest way to pull the engine out
http://pics.tdiclub.com/data/uploads//413482/DSC01435.JPG

2.5TDI Allroad 6 speed gearbox from the UK
http://pics.tdiclub.com/data/uploads//413482/DSC01438.JPG

Audi 80 flywheel: 026 105 269L ( New holes for the pressure plate bolts and the dowel pins have to be made)
Audi S2 pressure plate: SACHS 3082 919 001
Audi 100 2.5TDI clutch disk: SACHS 1862 625 001
flywheel bolts: 6X N902 06103
Pressyure plate bolts: 6X N014 7392
Passat/ A4 1.8t pilot bearing: 056 105 313C
RElease bearing: Allroad 2.7T 01E 141 165D

http://pics.tdiclub.com/data/uploads//413482/DSC014402.JPG

stp359 · Dec 11, 2015

The flywheel should arrive today drilled and balanced

yatzee · Dec 11, 2015

nice looking project. where did you find the tranny?

stp359 · Dec 11, 2015

yatzee said:
nice looking project. where did you find the tranny?

ebay.co.uk

yatzee · Dec 11, 2015

stp359 said:
ebay.co.uk

can i ask how much you paid with shipping and exchange?

stp359 · Dec 11, 2015

yatzee said:
can i ask how much you paid with shipping and exchange?

It came up to about 00$CAD with shipping and customs fees

stp359 · Mar 22, 2016

Finally I got it moving...It runs well except the vibration it has at low RPMs especially in higher gears. It's stronger under load but it vibrates even when I let the gas pedal off. It goes away if I barely give it gas not even enough to maintain the speed or above 1600RPM. I'm wondering if it could be from the BSM as I didn't remove it. I was thinking maybe it doesn't like the clutch assy as it's made to have a torque converter.
Any ideas guys?

LukeWilson · Mar 23, 2016

Did you have the entire clutch assembly balanced once the flywheel was modified? Is your balance shaft assembly timed correctly?

I wouldn't think the auto/manual swap would have much effect.

vwztips · Mar 23, 2016

There is no issue with the balance shaft with either a manual or automatic

stp359 · Mar 23, 2016

LukeWilson said:
Did you have the entire clutch assembly balanced once the flywheel was modified? Is your balance shaft assembly timed correctly?

I wouldn't think the auto/manual swap would have much effect.

Yes the whole assy was balanced. What do you mean if the balance shaft was timed correctly ?

LukeWilson · Mar 23, 2016

I would expect the balancer assembly would need to be timed to engine rotation, otherwise it will increase the vibrations instead of cancelling them. I think there is some kind of locking tool for the balancer assembly. I deleted the balance shaft on my car, so I've never actually done the procedure. I'm sure someone else who has done it would be able to comment.

Might be worth checking as the vibration isn't that bad in my car, sometimes it just causes interior trim rattles.

stp359 · Mar 23, 2016

The SMFW I have is about 19 pounds. Could it be too light for a TDI engine?... If the BSM is not a problem, I don't see any other possible cause. I drove both cars ( the passat TDI and the AR 2.7t ) before pulling everything out to build the AR and there were no virbrations in any of them

LukeWilson · Mar 23, 2016

People use a ~20lb G60 flywheel on ALH/BEW engines all the time with no issues, myself included. The worst I experienced from that set up was a slight rattle at idle, but no vibration once moving.

Any chance it's in the driveline? A bent output shaft or bad u-joint?

stp359 · Mar 23, 2016

I drove the car before swapping it and it was flawless. It gets worse past 2nd gear.

Windex · Mar 23, 2016

Does it make the same vibrations in neutral revving up?

If it is a flywheel imbalance, the vibration should be the same stationary or moving.

If it is moving only, then consider a driveshaft or engine / transmission mounts issue.

Was the stock differential the same ratio as the diff in the EU 01E?

stp359 · Mar 23, 2016

I can barely feel the vibration in neutral. The more I press the on the gas the worse the vibration. Until 1600rpm... The 2.5tdi and the 2.7t AR have the same diffs.

stp359 · Mar 23, 2016

Code letters EEY EHS EHT
Production from 06.99 10.99 10.99
to
Allocation Model Audi A6 1998 > Audi A6 1998 >
allroad quattro
without additional shift stage Audi A6 1998 >
allroad quattro
without additional shift stage
Engine 4.2 l - 250 kW - S6 2.7 l - 184 kW 2.5 l - 132 kW - TDI
Ratio Final drive 37 : 9 = 4.111 35 : 8 = 4.375 35 : 8 = 4.375
Z2 :Z1=i1st gear 28 : 8 = 3.500 30 : 8 = 3.750 30 : 8 = 3.750
2nd gear 34 : 18 = 1.889 35 : 17 = 2.059 35 : 17 = 2.059
3rd gear 33 : 25 = 1.320 34 : 24 = 1.417 33 : 25 = 1.320
4th gear 30 : 29 = 1.034 30 : 28 = 1.071 28 : 30 = 0.933
5th gear 30 : 35 = 0.857 30 : 35 = 0.857 27 : 37 = 0.730
6th gear 27 : 37 = 0.730 27 : 37 = 0.730 24 : 40 = 0.600
Reverse gear 38 : 11 = 3.455 38 : 11 = 3.455 38 : 11 = 3.455

Windex · Mar 24, 2016

If it does not happen in neutral, then the next thing I would do would be to put the car on a hoist or stands, and "drive" the car to the speeds where the vibration occurs and see if it is just as bad.

If so, then likely driveshaft.

If not, then likely engine mounts, or engine position - there is adjustability on those mounts (slotted) and it's possible to have the engine/trans in a position where it can ground against the firewall on acceleration. Also, check the snub mount at the front.

vwztips · Mar 24, 2016

stp359 said:
I drove the car before swapping it and it was flawless. It gets worse past 2nd gear.

Yes but you changed out the whole front drive train. Just the smallest thing can cause this.

On occasion I have had this with a Passat conversion. I loosened the 4 mount bolts and used a large crow bar to adjust the engine a little one way or the other. One trick I now do is bolt the subframe up tight before I tighten those 4 bolts.

Also check your exhaust. As Windex said if the front snub mount isn't doing its job it may allow the engine to rock backwards just enough to touch somewhere. I need to make a slight tweak and add a support to my exhaust system where the BHW down pipe splits to the dual exhaust.

I had my drive train in an A6 first and had significant vibration. I then installed the entire system in an AllRoad. The vibration went down significantly. I suspect something wasn't quite lined up in the A6. Also the snub mount sits higher in the AllRoad than it did in the A6.

stp359 · Apr 6, 2016

I still can't figure out why the cruise control does not work....

treyca · Apr 6, 2016

I like the run it in air on a rack in worst gears and watch drive shafts, engine, and trans for the vibration.
if its the transmission is geared for a gas engine there will be issues with cruise control and shifting timing

stp359 · Apr 6, 2016

treyca said:
I like the run it in air on a rack in worst gears and watch drive shafts, engine, and trans for the vibration.
if its the transmission is geared for a gas engine there will be issues with cruise control and shifting timing

The transmission is from a 2.5TDI Allroad from Europe. I don't think it is the transmission. On the passat it works.. It has a trasmission from an A6 2.5tdi which doesn't have the same ratios as the automatic transmission.

vwztips · Apr 7, 2016

I think I have asked this before, but have you checked in VCDS if the ECU is seeing the cruise, brake and clutch switch positions? If it is not seeing these and changing the 0's and 1's in the correct block, cruise will not work. In the ECU (01) it should be somewhere between measuring blocks 7-9 to see the status.

Also,

1. Do you have a tune yet?
2. If yes to 1, did you provide the gear ratios?
3. Has the ABS unit been coded in VCDS?

Scott_DeWitt · Apr 13, 2016

Does the vibration only occur while accelerating the car? Can you feel it in neutral? Does it change with the clutch pedal depressed?

stp359 · Apr 13, 2016

Scott_DeWitt said:
Does the vibration only occur while accelerating the car? Can you feel it in neutral? Does it change with the clutch pedal depressed?

Only under acceleration. It vibrates les when I let off the gas. No vibrations in neutral. Same thing with the clutch depressed. Only between under 1600 rpm. The more I press the gas the harder the vibration. It's really bad in 3rd and 4th . Looks like it it gets better at higher speeds. It might be just an illusion

stp359 · Apr 13, 2016

vwztips said:
I think I have asked this before, but have you checked in VCDS if the ECU is seeing the cruise, brake and clutch switch positions? If it is not seeing these and changing the 0's and 1's in the correct block, cruise will not work. In the ECU (01) it should be somewhere between measuring blocks 7-9 to see the status.

Also,

1. Do you have a tune yet?
2. If yes to 1, did you provide the gear ratios?
3. Has the ABS unit been coded in VCDS?

I have to check that out. Yes, I have a flash from a BGW engine from Europe but it looks like the abs module doesn't like it. It give a software management error...

Scott_DeWitt · Apr 13, 2016

Could be your transmission and/or the flywheel. I've had syncrho rings break with solid flywheels and the 1.9/2.0 with the 01E.

stp359 · Apr 13, 2016

Scott_DeWitt said:
Could be your transmission and/or the flywheel. I've had syncrho rings break with solid flywheels and the 1.9/2.0 with the 01E.

The vibration was there from day one. It's less noticeable in 1st and 2nd because the engine revs too fast but the vibration is there.

vwztips · Apr 13, 2016

So which gearbox do you have? The listing you show above has 3 listed. 2 of them are 4.38 and the other one is a 4.11 final drive.

I have a DQT (4.11). Mine "drones" when I "lug" it below 1600 in 3rd or higher. If I upshift a gear to 1800 RPM or higher, no issues. It does it worse when my family is in the car (adds 460-500#).

It reminds me of driving an old truck and choosing a higher gear before I should, getting out of the engine's sweet spot causing it to "lug" or vibrate throughout the cab.

My theory is being that the AllRoad is 800+ lbs heavier than the Passat it came in you need to chose a lower gear than you would in the Passat. I currently have a Passat BHW/GGB with 5 speed and stage 2 tune as well as the 2001 AllRoad with BHW/DQT and a stage 3 tune and larger turbo. The Passat never has this issue.

stp359 · Apr 13, 2016

vwztips said:
So which gearbox do you have? The listing you show above has 3 listed. 2 of them are 4.38 and the other one is a 4.11 final drive.

I have a DQT (4.11). Mine "drones" when I "lug" it below 1600 in 3rd or higher. If I upshift a gear to 1800 RPM or higher, no issues. It does it worse when my family is in the car (adds 460-500#).

It reminds me of driving an old truck and choosing a higher gear before I should, getting out of the engine's sweet spot causing it to "lug" or vibrate throughout the cab.

My theory is being that the AllRoad is 800+ lbs heavier than the Passat it came in you need to chose a lower gear than you would in the Passat. I currently have a Passat BHW/GGB with 5 speed and stage 2 tune as well as the 2001 AllRoad with BHW/DQT and a stage 3 tune and larger turbo. The Passat never has this issue.

The gearbox code is EHT. The allroad(1862kg) is almost the same wight as the passat(1749kg). The passat is the GLX 4motion model. I'm going to put the same clutch kit in the passat next week. We'll see what happens.

Audi Allroad 2.7T 6spd =» 2.0TDI BHW + 2.5TDI 6spd Allroad gearbox

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