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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old September 15th, 2016, 10:10   #31
DeliveryValve
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That looks like a straight and clean car. Too bad it's dead.
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Old September 15th, 2016, 10:12   #32
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It was. Absolutely perfect. I dechained it at 62k miles a few years back. Other than that it was an all original untouched car. You can see by the looks of the engine even, that still looks new!
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Old September 15th, 2016, 18:05   #33
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This is literally my dream. It would make the perfect utility vehicle especially in the winter.

I was going to do the same thing but start with a V6/4motion wagon since the V6 trans is very close to TDI ratios. But then I started thinking about all the FE hits from the slushbox and 4 motion and desided it wasn't worth the work. On the flip side they are REALLY nice cars. Saw a nice 4 motion wagon at the junkyard a few weeks back that was almost in perfect condition. Seems the values of those cars really tanked.

I ended up getting a almost free wrecked MK5 5cyl that I fixed up and now I am trying to figure out how to swap an ALH into that.
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Old September 15th, 2016, 18:41   #34
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The internal gear ratios on the FAL are 29/41 41/35 and 41/37.

The internal gear ratios on the GMR are 29/34 34/29.

The first two sets of numbers are the front output group. So in the GMR it has a 29 tooth input gear, a 34 tooth idler gear and a 29 tooth output gear. This gives it a 1:1 drive to the 3.09 front differential. The FAL has a 1.2:1(35/29) drive to the 3.09 front differential giving it an overall final drive ratio of 3.73. The rear axle ratio of the FAL is probably 4.10 so multiplying it by 37/41 would give you close to a 3.73 final drive ratio as well.

So even though the gear ratios of the main gears are the same, the output gears are different and therefore the final drive ratio. This will cause an error code. As will the torque converter slippage. You can change the output gears as I have done, but the output housings vary depending on the diameter/number of teeth on the gear, so you may have to change the housings as well.
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Old September 16th, 2016, 11:55   #35
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Thanks for the info, Reddok.

So if I am understanding correctly, there is a ratio for each of the gears (5 forward, 1 reverse), then the final drive ratio for the differential in the front of the case, but then this "third" change between the output shaft of the trans and the differential? I assume physically located at the rear portion of the unit?

Sorry for what sounds like a dumb question, just trying to understand. I've never torn into one of these units, never had to.

In other news, I tried plugging the TCM from the BHW car into my [other] AWM car, a FWD sedan. Car didn't like it, cluster went all lit up, like it was in limp mode, and I could not communicate with the TCM at all.

Plugged the original TCM back in, everything works normally. This may just be some incompatibility with the other modules, however... I would still think I should have been able to communicate with it, even if all it had to say was "I don't know where I am, what I am supposed to do, so I'll just sit here and do nothing".

But... I am assuming, possibly incorrectly, that both a 2004 AWM and 2004 BHW B5.5 would otherwise be using all the same communication protocols with all the modules. I cannot imagine why VAG would not use all the same stuff, so that the CCM, SRS, ABS, radio, etc. would all work the same regardless of what fuel goes in the tank.
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Old September 16th, 2016, 18:22   #36
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You sure it was the connector was seated all the way? If it won't communicate then the TCU wasn't even booting up...
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Old September 19th, 2016, 09:24   #37
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Ya, both 04 cars should use the same CAN bus version. I suppose it's possible they moved pins around on the computer but I highly doubt it.

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Old September 19th, 2016, 18:25   #38
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Quote:
Originally Posted by oilhammer View Post
Thanks for the info, Reddok.

So if I am understanding correctly, there is a ratio for each of the gears (5 forward, 1 reverse), then the final drive ratio for the differential in the front of the case, but then this "third" change between the output shaft of the trans and the differential? I assume physically located at the rear portion of the unit?
So there is the regular transmission gears 5 fwd, 1 reverse, then a reduction gear, then the final drive (ring and pinion) for the front diff. There is also a reduction gear for the rear differential as well.
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Old September 20th, 2016, 03:53   #39
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Quote:
Originally Posted by Reddok View Post
So there is the regular transmission gears 5 fwd, 1 reverse, then a reduction gear, then the final drive (ring and pinion) for the front diff. There is also a reduction gear for the rear differential as well.

OK, I understand now. Thank you. So the reduction gear ratio and the final drive ratio may not be the same front and rear as well, correct?

This is looking more and more like I will need to convert it to a manual. Was hoping to do a quick engine swap along with a couple modules and call it a day.
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Old September 20th, 2016, 04:07   #40
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Here is the crashed car still on the trailer. I have to get some more pieces out of it.



Here's my Sport Utility Variant, patiently awaiting its TDI transplant (and probably leaving an oil stain under it from the leaky AWM ):



The Vanagon behind it would also like a TDI transplant, but it is already a diesel (and a manual ) so that might be a bit easier!
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Old September 20th, 2016, 05:18   #41
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Perhaps you could find someone who can tune the trans computer.

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Old September 20th, 2016, 05:31   #42
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Quote:
Originally Posted by compu_85 View Post
Perhaps you could find someone who can tune the trans computer.

-J
I was thinking about that. In my [non expert] analysis, it would be a matter of overlaying the expected gear ratio values from the FAL TCM into the GMR TCM.

I am still scratching my head over the lack of communication I had when I put it in this other AWM car. KWP2000 is the communication protocol that VCDS shows for both of them.
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Old September 20th, 2016, 06:03   #43
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Just swap the BHW trans in and run without the 4motion. You could always find the appropriate 4motion auto trans and TCU from Europe later.

You need to get the wiring diagrams for both TCUs and compare them. Any chance the BHW one was water damaged? They are known to have that happen sometimes.
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Old September 20th, 2016, 06:05   #44
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No, no chance. It was a running driving car when it was crashed. Car was near perfect, never any water intrusion of any kind. I have taken care of it since it was new.

I will look over the diagrams at lunch today, if I have time. Busy day ahead of me. And the other Volkswagen guy left us, so I am all alone now.
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Old September 20th, 2016, 10:01   #45
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Well it looks like dumbass Alldata doesn't have any wiring diagrams for the TCM and harness. And that's why we call it "Somedata".

They do have a pinout for the SST VAG1598/20 breakout box.
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