Manual Swap Video B5.5 Passat TDI How-to

stamp11127

Veteran Member
Joined
Jan 20, 2016
Location
Temple, Ga.
TDI
2002 Jetta GLS 2003 Jetta 5sp 2005 Passat Wagon 5sp project
I watched it & picked up some additional info that will help with my swap. It would also be nice if you added part numbers for the clutch parts you used and how well that combination is working.
 

Jesus Is Lord

Veteran Member
Joined
Jan 24, 2014
Location
Hersey, MI
TDI
2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
I watched it & picked up some additional info that will help with my swap. It would also be nice if you added part numbers for the clutch parts you used and how well that combination is working.
The clutch is working great, and besides a slightly heavier pedal, it engages very smoothly.

Stage 3 Daily South Bend Clutch Kit - K70205-SS-O-DMF
(Includes Throw Out Bearing)

LUK flywheel - DMF039

Pilot Bearing - 394 54015 279 or 056105313C

Flywheel bolts - N90665001
(6 required)
 
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oilhammer

Certified Volkswagen Nut & Vendor
Joined
Dec 11, 2001
Location
outside St Louis, MO
TDI
There are just too many to list....
I think I am going to have to do one, too, but mine is a 4mo. So it is getting an engine swap as well.

Nice job on the video!
 

stamp11127

Veteran Member
Joined
Jan 20, 2016
Location
Temple, Ga.
TDI
2002 Jetta GLS 2003 Jetta 5sp 2005 Passat Wagon 5sp project
Levi, I came across your video on removing the automatic trans. Good info in that too. Suggest putting a link to it in your first post for future readers.
 
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Majder

Member
Joined
Aug 19, 2016
Location
Calgary, AB/Creston, BC
TDI
2005 Passat Wagon, 2003 Jetta Wagon, 2012 F350
Excellent post! I am rapidly loosing interest in trying to fix my auto box. What was the part number for your new mount? I see you installed the FHN trany. Where did you find it? I am considering the DUK trany, but my concern is the first gear is a higher ratio and may cause a chatter. Anyone have any thoughts on that?
 

89vr6

Veteran Member
Joined
Sep 11, 2012
Location
Clarksville,TN
TDI
2000 base
Excellent post! I am rapidly loosing interest in trying to fix my auto box. What was the part number for your new mount? I see you installed the FHN trany. Where did you find it? I am considering the DUK trany, but my concern is the first gear is a higher ratio and may cause a chatter. Anyone have any thoughts on that?

Frans on here sells just the transmissions or he'll sell a complete kit for the entire swap
 

zzdiesel

Veteran Member
Joined
Dec 10, 2010
Location
sask. mostly now Wa.
TDI
05 passat tdi Geared BSM and Bewcam 2nd 2005 deleted ,converted and bew cam stage 2 Malone3 tune.
Is there a suitable transmission for a tdi swap into the 4motion?
 

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 have installed and driven both the DUK and FHN. There is no real world difference that you can feel. In fact there is no real difference in MPG either. No idea what you mean by chatter either.

Personally if I could get my hands on a 5 speed Quattro TDI gear box I would prefer it over the six speed.
 

Jesus Is Lord

Veteran Member
Joined
Jan 24, 2014
Location
Hersey, MI
TDI
2005 Passat TDI Wagon 144,000 2003 Eurovan VR6 2007 Touareg V10 TDI 158,000
Stock Dual Mass Flywheel, and a South Bend Stage 3 Daily Clutch.
 

otty

Veteran Member
Joined
Nov 7, 2010
Location
Revelstoke, BC
TDI
2003 Passat W8=>TDI swap, 4Motion Wagon, PD130(AVF) 6Speed Manual, 2006 Jetta MKIV PD(BEW) Wagon 5Speed Manual
Great video, thanks.

Where can I buy the two wire connector that connects to the clutch switch '(for cruise not the starter interlock switch)? No junkyards for a long way from where I am. Any idea where I can buy something like that?

Thanks.
 

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
Vw. I will try and look up the part #
 

otty

Veteran Member
Joined
Nov 7, 2010
Location
Revelstoke, BC
TDI
2003 Passat W8=>TDI swap, 4Motion Wagon, PD130(AVF) 6Speed Manual, 2006 Jetta MKIV PD(BEW) Wagon 5Speed Manual
Thanks but I just looked and there is no clutch switch in there at all! I am ordering one from Roseland. Hopefully it will work. I think they have the wiring harness as well.
 

rocketboy52

Veteran Member
Joined
Jan 13, 2010
Location
Tehachapi CA
TDI
2004 Passat TDI
Thanks but I just looked and there is no clutch switch in there at all! I am ordering one from Roseland. Hopefully it will work. I think they have the wiring harness as well.

Otty did you ever get this resolved? Do you have the part numbers? I'm looking for the same parts.

Thanks!
 

TdiBoyNZ

Member
Joined
Jan 2, 2016
Location
New Zealand
TDI
2002 Passat estate. Avf 130PD
With the clutch switch wiring, is the switch open when the pedal is pressed or closed when pressed??
I have a switch from an Audi but want to be sure It’s the correct polarity switching before I fit it, cheers
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
Just jumper the connector and disable the starter clutch switch. You trust bearings will thank you!
 
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