B5.5 Wagon 4mo 1.8t Auto to Tdi Manual

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
I’ve scored one of these for a decent price and I’m goung to slowly assembly all the parts I need for this.
With that said..
I’ve contacted Frans and want to make the most out of an order from him.
What engine should I go with?
What about cluster?
I want to make this a turn key car almost as if stock.
I’m guessing the rear diff needs to match the transmissions final drive?
What other considerations should I take into account?
 

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
posting for reference and if others ever need the info.
From Frans:
A full swap including engine and drive line is €3700 shipped
-Engine with all attachments. And engine wiring (new timing belt, included, not installed) Engine is a PD130 AVF/AWX, it doesn’t have a balance shaft module.
-new dmf flywheel and clutch assembly
-shifter assembly 6 speed
-6 speed starter
-6 speed spacer
-gearbox 6 speed tdi
-front axles
-prop shaft 6 speed.
-rear diff (4.11)
-pedal set and clutch hydraulics

All above but without the engine is €2300 shipped
 

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
I said to Frans:
"Do the 4motion 6 speeds have the same issue with the pinion bearing(as the FWD 6 speeds)?


Is an 01a 5 speed driveline available less engine? Is the AFN motor an option?"

His Response:

"No the 4motion gearboxes don’t have this problem.

The 01a 5 speeds are super rare and not as durable as the 6 speeds. AFN engine is also possible. It will fit in front of the 6 speed Quattro."
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
I don't recommend the SMF with 4 motion set up. I tried it and did not go well.
 

bbob203

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Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
looks like I will be sourcing an 01a 5speed from the UK and a 3.889 rear differential(to match the 01A final drive) from a C5 Audi A6 2.8 Automatic this available stateside.
 

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
MikkiJayne has brought to my attention that the driveshaft I would need for this setup may well not exist and I would have to go custom. I may just go with the six speed setup from Frans..
 

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
Leaning toward ALH

I’ve got a donor Mk4 jetta that I thought was salvageable after puttinf it into a ditch but it may be worth more as a donor.

I know I’ll need:
BHW mounts/brackets
1.8t AWM oil pan and pickup tube
Different turbo
Complete ALH harness
PD manifold

What else?
 
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bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
Decided to go the route of an automatic. I picked up this Custom rebuilt 5hp19FLA TDI geared 4motion transmission and rebuilt bv43a turbo. Time to make a 4motion variant!
To build this he used the input shaft from a gasser 5hp19fla and installed it into a bhw 5hp19fl(fwd version) then added the center diff(from the gasser trans) and the proper reduction gears to make it all work.

 
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bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
i'm back working on this project. Trying to figure out the wiring I don't want swap the dash harness I want to change the existing 1.8t wiring to work with the BHW. Anyone know what wiring needs changed?
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
I did it 2 years ago. You just need to get 1.8t wiring diagram and TDI diagrams and comoare the 2 to figure out what to change. IIRC the fan harness is slightly different too.

Frankly yoy can pull the dash and harness in the amount of time it will take to figure out the wiring. I have done it that way too.
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
You can also install a new heater core and insure yiou will have heat
 

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
Pulling it was a nightmare and it kinda intimidates me to hook it back up if I can just change a few wires. I know some of the connections in the side kick panels aren’t unique and can be plugged into the wrong connections and cause problems.
 

bbob203

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Joined
Oct 31, 2012
Location
Louisville, ky
TDI
b5.5v
Finally getting this project off the ground.
ALH motor with 11mm pump bv43a turbo and .280 injectors with FMIC
Custom GMR 01v AWD transmission
Custom AVF B5.5 121 harness converted from PD to VE.
Will also be adding Trinity DMS lift kit
Dash swap from TDI car to make wiring simple
3.889 rear differential to match transmission
Added ESP
 
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