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VW B5 Passat TDIs This is a general discussion about B5 Passat(>98 (2004-2005 in North America)). Non TDI related postings will be moved or removed.

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Old May 16th, 2019, 16:01   #316
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No need for G85 calibration
good to know, have you ever had the persistent 16955 code ? and if so, how did you solve it?
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Old May 17th, 2019, 10:35   #317
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FIXED! ecm 94/65, ws/ro had gotten pushed out of the connector... code cleared and all switch positions in vcds are good to go*
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Old May 17th, 2019, 10:37   #318
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Nice, good work!
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Old May 17th, 2019, 10:39   #319
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Good to know. I have done over 30 conversions and had not seen that error before.

FWIW there is a different procedure if you have a Bosch 5.3 ABS
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Old May 17th, 2019, 11:02   #320
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Nice, good work!
thanks! but i feel like a dope for not running this down sooner... i need to pay more attention to the label file next time
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Good to know. I have done over 30 conversions and had not seen that error before.

FWIW there is a different procedure if you have a Bosch 5.3 ABS
this is my FIRST B5.5 swap and i feel like every pitfall that existed i fell into... is the 5.3 procedure wildly divergent from the 5.7?
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Old May 17th, 2019, 11:28   #321
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The 5.7 ABS you have to log in like you did and change the ABS code

The 5.3 ABS is just a straight soft code change with no log in required. However there is no corresponding soft coding for a FWD 5 speed. You have to code it as a 6 speed and IIRC AWD. Really don't know why it calls out a 6 speed specifically
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Old May 18th, 2019, 19:15   #322
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long shot; does anyone have a clutch masters fx series on the shelf they could perform a quick measurement on and snap a few pics of ?
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Old May 18th, 2019, 20:51   #323
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I have a stock 240mm DMF and Sachs SRE on the shelf....
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Old May 20th, 2019, 07:52   #324
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long shot; does anyone have a clutch masters fx series on the shelf they could perform a quick measurement on and snap a few pics of ?
I do. Txt me what you need. 262-370-9647
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Old May 20th, 2019, 07:59   #325
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Is this a 4motion or FWD?
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Old October 12th, 2019, 10:12   #326
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Post Custom pilot bearing

I found a great solution to the issue of not having enough transmission input shaft engagement in the pilot bearing. I bought an HK1522 (21mm OD, 15mm ID, 22mm long) drawn cup needle bearing and a 21mm OD, 15mm ID, 3mm width oil seal to keep the grease in the bearing and the dirt out. I got the seal and bearing from a local bearing supplier for about $7 each. The original pilot bearing is 16mm long with a built in oil seal which reduces the amount of the rolling element length to about 15mm. I took a piece of mild steel drilled it 20mm deep with an 11/16Ē bit bored it to 14mm deep about 20.95mm diameter (basically just a press fit for the bearing.) Turned a 45 deg. chamfer 4mm from the end of the bar stock to support the bearing inside the chamfer in the crank. I turned the diameter of the material to 0.25mm smaller than the flywheel bore which is around 35mm +-5mm (I donít remember the actual size). I parted the bar stock off at 17mm long. This gives me 11mm of bearing engagement in the crank and 11mm in the bearing and seal retainer I made. The total input shaft support is about 14.5mm. I installed the oil seal with the numbers facing the bearing to prevent dust getting in the bearing. I have not had a chance to run my car after installing the new clutch but I sure this bearing setup will work great.




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Old October 15th, 2019, 14:29   #327
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Is this necessary at all?
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Old October 15th, 2019, 15:07   #328
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Is this necessary at all?

Depends, I guess. If you want to run a 240mm clutch and dual mass flywheel, then you need a 5mm spacer between the engine and transmission, which can reduce engagement in the pilot bearing to less than 3mm (not nearly enough). This solution would resolve that issue. In my case, I'm running a 228mm clutch and dual mass flywheel, so I don't need a spacer. That means my pilot bearing gets plenty of engagement. I recently inspected it after 2.5 years and 35k hard miles, and it's in perfect shape.
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Old October 15th, 2019, 17:43   #329
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I drove mine for almost 5 years without issue. I still haven't taken the car apart yet, but it drove to its current rusting place.
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Old October 16th, 2019, 14:07   #330
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Default 6 speed shifter assembly

Hi, does anyone have the part number for the 6 speed shifter assembly for the Passat auto to manual conversion
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