sunvalleylaw
Veteran Member
Start to Finish B5.5 conversion/project thread
This thread is my attempt to document from start to finish my 2005 Passat project. It is not intended to be a "how to" thread, as I am not a mechanic, and though will be documenting the process as well as I can, I will not be the one doing the work. If anyone learns anything from my experiences, awesome! I will come back and list some threads to look at if you are considering the manual swap that may be a better place to look for "how to's".
I am buying 2005 Passat Wagon GLS with a blown tranny, and with the help of my local mechanic, converting it over to manual, deleting the BSM, adding a tune, and considering a camshaft, (either right away if needed, or later if this one is ok for now). This will be a work in progress, and the various mods listed will be done over a period of time.
Here is a quick pic of the car taken by the seller:
I will post a couple more after the car arrives sometime this next week, and plan to post progress pics as I can.
2005, GLS, Wagon, Dark Blue with grey leather, 112k original miles, two owners, the original for less than 2 years, then the current seller.
Prior to purchase, I had it inspected at a shop:
The bad:
-blown tranny (not shifting correctly in 2nd and 3rd, slipping and limp mode) also pan is leaking.
-Front passenger door lock assembly thinks door is closed all the time. -Needs to be replaced.
-Headlights lenses hazy.
-Minor bearing noise from viscous fan bearing.
-BSM still original, but no chain noise. (will delete anyway).
-very slight valve cover leak.
-One of the 17" Bistars is missing a center cap.
Good:
-two owners, all services done. Timing kit at 75k (now 112k)
-All other systems in good shape an operational. Other than a very slight noise in front lower control arm bushings. (will likely address that in the next year or so).
-Overall a good, relatively clean (though needs a detail), rust free, operational (other than tranny) car.
Other condition notes:
Exterior: minor and typical scratches, no big chips, no dents, no accidents,
no rust (had them look well for it, specifying known rust issues).
Interior: leather in very good shape as is the interior generally. Single guy,
no kids or pets so back is not worn. But generally needs a good
clean/detail.
Summer tires (conti extreme contacts) have one summer left on them, but that is it.
Looks from receipts like he used ok oil. 5w40, 505.01 Castrol or valvoline syn power. (edit: looked at more receipts, looks like some 5w30 snuck in there on a change or two early on. Going to plan on a cam at some point).
Basically seems to be a generally well maintained, pretty much stock car.
Initial plans:
-manual conversion with DUK gearbox, 1.9TDI clutch (ordering from Frans)
-Delete balance shaft
-consider doing timing kit again seeing as we will be in there.
-Tune ECU (considering Malone Stage 2 with Flashzilla, more on that below)
-check glow plugs (did not remember to get that checked) to see what I have and either tune appropriately or replace as necessary for cold starts.
-consider doing camshaft. (may do right away, or may wait until after remainder of initial project accomplished. also depends on overall cost of initial project).
-install my already purchased steel rims and snows.
-get a good detail
-Enjoy.
My local mechanic, with backup from a local TDI guy who converts Vanagons to diesel, will do the heavy lifting. I will help as much as I can. I hope that he and I will get to know the car very well through this process.
So this is the current plan, and as with all plans, things may shift. Open to all advice and comments as I go. I have been reading lots of threads on the conversion process, cams, tunes, glow plugs, rust handling/prevention, etc. So much good info to find here if you look. Thanks!
I am intending this thread to be one person's journal of a project, reviving a blown tranny car, and hope that the thread will provide some decent info. It will also be fun for me to track it as it goes.
One initial question is whether I am planning out this project in a logical, cost effective way. I want to be effective with labor as I go, so want to take care of things that make sense. But I can't really afford to gut the whole car and rebuild the whole thing in one bite either. So looking for a balance there.
One big question there is the cam. I will probably push that part off unless I really have to do it now. But maybe not if budget allows after the tranny aspects are more or less purchased and labor budgeted and known. As stated, input welcome. Thanks all!
This thread is my attempt to document from start to finish my 2005 Passat project. It is not intended to be a "how to" thread, as I am not a mechanic, and though will be documenting the process as well as I can, I will not be the one doing the work. If anyone learns anything from my experiences, awesome! I will come back and list some threads to look at if you are considering the manual swap that may be a better place to look for "how to's".
I am buying 2005 Passat Wagon GLS with a blown tranny, and with the help of my local mechanic, converting it over to manual, deleting the BSM, adding a tune, and considering a camshaft, (either right away if needed, or later if this one is ok for now). This will be a work in progress, and the various mods listed will be done over a period of time.
Here is a quick pic of the car taken by the seller:
I will post a couple more after the car arrives sometime this next week, and plan to post progress pics as I can.
2005, GLS, Wagon, Dark Blue with grey leather, 112k original miles, two owners, the original for less than 2 years, then the current seller.
Prior to purchase, I had it inspected at a shop:
The bad:
-blown tranny (not shifting correctly in 2nd and 3rd, slipping and limp mode) also pan is leaking.
-Front passenger door lock assembly thinks door is closed all the time. -Needs to be replaced.
-Headlights lenses hazy.
-Minor bearing noise from viscous fan bearing.
-BSM still original, but no chain noise. (will delete anyway).
-very slight valve cover leak.
-One of the 17" Bistars is missing a center cap.
Good:
-two owners, all services done. Timing kit at 75k (now 112k)
-All other systems in good shape an operational. Other than a very slight noise in front lower control arm bushings. (will likely address that in the next year or so).
-Overall a good, relatively clean (though needs a detail), rust free, operational (other than tranny) car.
Other condition notes:
Exterior: minor and typical scratches, no big chips, no dents, no accidents,
no rust (had them look well for it, specifying known rust issues).
Interior: leather in very good shape as is the interior generally. Single guy,
no kids or pets so back is not worn. But generally needs a good
clean/detail.
Summer tires (conti extreme contacts) have one summer left on them, but that is it.
Looks from receipts like he used ok oil. 5w40, 505.01 Castrol or valvoline syn power. (edit: looked at more receipts, looks like some 5w30 snuck in there on a change or two early on. Going to plan on a cam at some point).
Basically seems to be a generally well maintained, pretty much stock car.
Initial plans:
-manual conversion with DUK gearbox, 1.9TDI clutch (ordering from Frans)
-Delete balance shaft
-consider doing timing kit again seeing as we will be in there.
-Tune ECU (considering Malone Stage 2 with Flashzilla, more on that below)
-check glow plugs (did not remember to get that checked) to see what I have and either tune appropriately or replace as necessary for cold starts.
-consider doing camshaft. (may do right away, or may wait until after remainder of initial project accomplished. also depends on overall cost of initial project).
-install my already purchased steel rims and snows.
-get a good detail
-Enjoy.
My local mechanic, with backup from a local TDI guy who converts Vanagons to diesel, will do the heavy lifting. I will help as much as I can. I hope that he and I will get to know the car very well through this process.
So this is the current plan, and as with all plans, things may shift. Open to all advice and comments as I go. I have been reading lots of threads on the conversion process, cams, tunes, glow plugs, rust handling/prevention, etc. So much good info to find here if you look. Thanks!
I am intending this thread to be one person's journal of a project, reviving a blown tranny car, and hope that the thread will provide some decent info. It will also be fun for me to track it as it goes.
One initial question is whether I am planning out this project in a logical, cost effective way. I want to be effective with labor as I go, so want to take care of things that make sense. But I can't really afford to gut the whole car and rebuild the whole thing in one bite either. So looking for a balance there.
One big question there is the cam. I will probably push that part off unless I really have to do it now. But maybe not if budget allows after the tranny aspects are more or less purchased and labor budgeted and known. As stated, input welcome. Thanks all!
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