imo000
Top Post Dawg
Last week I picked up a ’05 Passat sedan with 250K Kms, and a transmission that leaked out the fluid and eventually burnt up the friction surfaces. After hunting for a replacement automatic transmission and coming up short with anything that was near or in good condition, decided to talk to Windex and get some pointers on the finer details of his swap (I didn’t see his write up until after our conversation). After our 45 minute conversation, I decided to change direction with this project and convert the car to a manual 5-speed instead. I’m not looking for any kind of horsepower improvement in the engine and since this car will only be my daily commuter, I decided to do a very low budget conversion (have other cars that I have fun on the weekends).
The following day picked up an FHN transmission from a local importer for $725. The transmission came with the slave cylinder and he threw in a used clutch set too. The clutch set looks good but the disk shows more wear that I would prefer therefore, I will either reline it or replace it completely. The flywheel and the pressure plate are in good enough shape to reuse. The release bearing will probably be replaced too. I do all my own work on all my cars so my perception of “worth reusing” might be different than for someone that pays for the labour and/or don’t have a “back up” car.
Today I picked up two axles from a 1.8T Passat for ($35/ea.) and a shifter box form a manual Passat for $80. On the weekend I’ll go and start looking for the pedal, master and associated line/switches. I will see if the existing transmission mounts can be modified and reused. I have access to a machine shop so the pilot bearing will be made there or will make a sleeve or two to accept a standard off the shelf bearing.
I’ll post pictures of the parts a little later and update this thread as the project progressed. The plan is to get the car on the road in about a month.
The following day picked up an FHN transmission from a local importer for $725. The transmission came with the slave cylinder and he threw in a used clutch set too. The clutch set looks good but the disk shows more wear that I would prefer therefore, I will either reline it or replace it completely. The flywheel and the pressure plate are in good enough shape to reuse. The release bearing will probably be replaced too. I do all my own work on all my cars so my perception of “worth reusing” might be different than for someone that pays for the labour and/or don’t have a “back up” car.
Today I picked up two axles from a 1.8T Passat for ($35/ea.) and a shifter box form a manual Passat for $80. On the weekend I’ll go and start looking for the pedal, master and associated line/switches. I will see if the existing transmission mounts can be modified and reused. I have access to a machine shop so the pilot bearing will be made there or will make a sleeve or two to accept a standard off the shelf bearing.
I’ll post pictures of the parts a little later and update this thread as the project progressed. The plan is to get the car on the road in about a month.
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