B5 Passat TDI manual transmission swap

Quote:
Originally Posted by QuickTD
At the ECM 94 pin connector, remove pin from 59 (grey wire) and insert into 43 (vacant). Then release the grey wire at pin 1 of the accelerator pedal, untape the harness a short distance and hook the grey wire to one side of the clutch switch pigtail. Tap into the red/white wire at the brake switch and connect it to the other side of the clutch switch pigtail. Re-tape the harness. Done.
For a real class act you can install the clutch safety starter interlock switch as well. Locate the starter interlock relay at position 13 of the large relay panel (2nd row, last relay). Expose a good length of the brown white wire at pin 6 and cut it. Connect the relay end of the wire to the clutch interlock switch. Connect the other wire from the interlock switch to a good ground, any brown wire behind the relay panel will work.
Wire from lower clutch switch spliced with gray wire from pin one at accelerator.
The other wire splices into the red and white wire on the brake switch.
Wire from lower clutch switch spliced with gray wire from pin one at accelerator.

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The other wire splices into the red and white wire on the Brake pedal.

Mine is doing very well thus far. Went one step further and deleted the BSM last Friday. Then, Saturday morning drove 4.5 hours into the Smoky mountains. Stayed at a cabin up there, hit the lake a few times, deals gap, etc...and drove home today. Haven't refueled yet, but the guesstimated average looks good! It was dam near spot on with my last tank of city driving with the BSM still in @33.5mpg (with the V6 gasser trans). This is also with 3 adults, full luggage, and driving way too fast following my buddies TDI Touareg.

My Passat took it's first real 5 speed voyage yesterday! I bought it with a bad auto and never knew how it really drove before, but I can't believe how amazing it drives now. Ended up with a 33.1 MPG average, which was awesome considering it was all windy, mountain roads with a lot of elevation changes and accelerations between the corners. A Miata had to pull over to let me by.

I have to give a shout out to KermaTDI. Every swap I've seen so far has used Malone to handle the ECU tuning. I like to keep my patronage as local as possible and Kerma is less than an hour away, so I sent it to them. Anyway, the results are awesome! All faults resolved and the power is amazing. Just figured I'd put that out there as an additional tuning option for prospective swaps anyone is contemplating.

Along with Kerma and Malone, I will also give a shout out to TDTuning for my conversions.

+1 for TDTuning.

+1 for TDtuning. I have 2 TDIs with Mike's tunes, really like them.

I've found Mike's tunes a bit too aggressive on the boost "tip in" making for not as smooth of a drive. Kind of like driving a GM product.

Actually, when I did my first conversion on a 5 speed, I purchased a programmer box from Mike and he and I went back and forth several iterations to get the program just right. I have had no issues with "tip in". All is nice and smooth and when desired, lots of punch as well. I am very happy with the program as well as quite a few others.

But to each his own preferences.

Tip in = when boost comes on?

"Tip In". I now have the technical name.

I also have Mikes tune and seem to have turbo lag or tip in. At first I thought it was the way I was driving and not getting on it enough.
But i notice its very dead below 2k reevs.

To be fair to Mike I haven't addressed this as I'm just recently daily driving it and getting used to tune.
I have the 2.0 tune with DUK 5 speed.
It will chirp the tires into 2nd gear if you get that turbo spooling.

I can't say enough about service on Mike part. I mailed Ecu on Monday and had it back by Saturday. Answers e mails within a couple hours.

Chrismak, you have a geared BSM too, correct?

Yea i had Jason do the balance shaft when issue first surfaced on boards.

You just do the delete right? On a side note, what mounts did you use for the gearbox?

I have a definite click or grab when changing gears. Probably not as bad as it sounds when re reading that, but tou know what I mean.
Like my mounts are bad.
I did replace engine mounts a couple of years back and they seem ok on visual inspection.
What about that snub nose on front of engine?
I believe thats supposed to have a little play. Wow now I'm talking to muself

I have a delete. Stock mounts.

Check and make sure all mounting bolts are tight. Even the slightest looseness will do what you are describing.

Checked the underpinning and i had to re tighten the bolts that hold the engine mount brackets. Not much but did het a half turn.
Also bolts on the rear bracket subframe that bolt to body were loose. I originally loosened to drop subframe down to remove tranny. The main one on bushing got a couple turns.
Then i managed to shear one of the smaller ones on bracket to body. Turning with 1/2 inch rachet and no extension. What the heck.
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I also have a Chinola axle that I got off donor car and just put it in to get up and running. The boot on wheel side is leaking and I believe the linkage is a bit sloopy so that may be contributing as well. I have sourced a VW axle and it will be changed Monday.
Now to get that sheared bolt out.

Just drill and tap it. It will be fun drilling upwards.

Better yet go out and buy a left handed drill bit
Once they grab they will back the broken bolt right out!

^this. I love LH drill bits.

Good consolidation of info in this thread. One bit of information that I have not been able to source has been how to get cruise control working properly. I have an '05 Passat with a DUK gearbox and TDTuning flash. After wiring in a clutch switch I get cruise control working in 2nd and 5th gears with partial operation in 3rd. I wonder if ABS module coding dictates what gear ratios will be compatible with cruise? If so, what coding might make cruise control work as it should?

Thanks for the input, TD. From past experience I was not expecting cruise to work below ~25 mph and I am really not worried about cruise in gears lower than 5th. However I had not found any threads where cruise wasn't fully sorted out so I just wanted some feedback from others that have done this swap.

My TDTuning 4th gear cruise did not work when I got my ECU shipped to me. I e-mailed Mike but never heard back. Then I changed my tune to GDE and they have offered to fix this issue but I have to run the car is certain gear/rpm/speed and report back and I have not gotten around doing it yet.

Good to confirm that my car wasn't the only one, tikal. Thankfully, the vehicle passed emissions testing after the flash and I could not be more pleased with the result of the swap.

Need help here, there was a post of a complete trans swap, auto to 5 speed on a Passat, model years was between 2000 to 2005, can't find it, had lots of pic's. Thanks, Col. ( Try my chicken )

Here's the main pages I used when I did mine. Google is amazing...

http://forums.tdiclub.com/showthread.php?t=420182
http://forums.tdiclub.com/showthread.php?t=415887
http://forums.tdiclub.com/showthread.php?t=378108
http://kansascitytdi.com/passat-5-speed-manual-trans-conversion/

Read up! I pulled a little from every one of those pages.

tikal said:

My TDTuning 4th gear cruise did not work when I got my ECU shipped to me. I e-mailed Mike but never heard back. Then I changed my tune to GDE and they have offered to fix this issue but I have to run the car is certain gear/rpm/speed and report back and I have not gotten around doing it yet.

Click to expand...

Sorry about this issue. I think it's possible I need to change hosting as I don't think all e-mails are making it to/from me. I've noticed it seems there may be some discrepancies in the gear ratios between what is listed for replacement parts from VW, and what is actually in some of these transmissions. Obviously that can be for several reasons, but it doesn't really help the situation.

Shoutout to Mike for working with me on lag issue and low mileage.
Turns out i had a bad N75 valve and wasn't boosting on low rev's.
Then I had brain fart and was reading the cluster in #2 mode and the mileage was showing like 34mpg.
Then while shooting video I realised it was in cluster 2 instead of 1 DAH.
Sl all good now and I pulled yhis mileage on highway on way home yhis afternoon.
About that left handed drill bit mentioned above, i did find one if anyone needs to borrow it. Just make sure you have a left handed drill before you use it.
Actually that drilled out really easy and the broken piece screwed on through the body into a cavity in frame.
Thanks again Mike.

This MPG is excellent. I have never seen this kind of MPG. Thats highway commute with some braking from 75-80 down to 45-50.

That gaugenis not that accurate. Calculate the consumption after a few tanks.

Some good info and pics in this thread. Thanks everyone!

Windex said:

http://forums.tdiclub.com/showpost.php?p=4115670&postcount=11

Click to expand...

Trying to recode ABS without any luck so far. I have removed TCU, recoded CAN gateway, recoded ECU w out issues but for some reason the suggested coding won't be accepted by the ABS unit...99% done with this 5spd swap...any suggestions? I have exhausted my references at this point and Ross-Tech can't help since this combination (Passat TDI+manual) was never offered.

Have you reflashes the ECU with a "tune" from a runner to a manual transmission? That's the first step, everything else you did pretty much comes after.