01M swap to 5 or 6 speed manuel transmission?

The recent thread about converting a manuel to a DSG got me wondering...

Has anyone ever converted an 01M automatic to a manuel transmission?

If I ever lose the 01M, I think I would rather convert it than rebuild the auto, if that's doable...

I have not heard of anyone doing it as of yet, but I have been looking into it for some time now. The problems that I see are the wiring, cluster and the ECU. I believe that the ECU will just need soft code changed, but not sure.

I will ask RocketChip Jeff at tomorrow's GTG in Atlanta...

I forgot to ask him... 9 hours waiting for my turn in the chipping line in the baking heat melted my brain... The up side was my car was less than a 10 minute chip job with no problems at all...

Sport mode and RC II makes me like the 01M a whole lot more than I did before...

No change in mileage so far but the car gets to 100 mph LOTS FASTER!!! In fact, what used to be a struggle to get up to 60 mph merge speed on short ramps entering the highway is now an easy 100+ mph...

Keep sniffing around for me and figure out how to convert the 01m to a 6sp manual though. I want to know how to do it too.

I don't know how you'd install the clutch pedal though.

get the pedal assembly parts from a gasser?

Bringing this back from the dead...

I am *very* interested in losing my auto, esp since it's not even the original one in there... Long story, but I don't even want it anymore...

My 99 Golf has all of the holes in the firewall for the hydraulic clutch stuff, and even a "short" brake pedal...

The biggest difference should be the PCM program, the harness, the cluster has the PRNDL in it, halfshafts (CVs, whatever), and flywheel... As for the Rodents of Unusual sizes... I don't think they exist.

I've done a bit of sniffing around. I think that you'll need to change these parts to convert it.

Obviously the transmission. An 02J can be had used for not too much, but make sure to get an 02J from a TDI due to the gearing. Now's a good opportunity to throw a VR6/G60 combo on it too and put a taller 5th in. The VR6 02J has the same final drive ratio as the TDI 02J, but you'll definitely need to throw a new 5th gear into it. The bellhousing is also different, so to get it to bolt up to the engine you'll need to swap bellhousings. You can get a broken 2.0 02J to be a bellhousing donor.
New transmission mounts
Clutch pedal. The firewall and liner already have cut outs for where to install this.
Starter motor. I think that the starter for the manual and auto are different.
Shifter and cable assembly. Good opportunity too to drill a hole in it and make it a short shifter.
I think that you'll need a TCU for cruise control at least. Not entirely sure about it though. You'll need a new ECU, so give Jeff a call.
Obviously all of the bolts and crap.

Thanks, Now I've got a weekend project!

You should be able to reuse the same axles without a problem, unless you opt for a vr6 tranny, which will have larger flanges so you'll need larger axles. I am trying to locate a complete used package of the same thing myself so I can swap transmissions.

oooooooh... so my $2008.88 isn't going to waste?

Lol! Btw, didja ever get thy money back from the dealership for that job? $1k for a single CV joint. Lollers. I'm rebooting a CV joint tomorrow, hopefully it won't turn into a problem like that

Nope, I just chalked those axels up to the school of real life. Those CVs better work for 100k+ miles, and then be rebuildable... twice.

I'm going tomorrow to see if I can get a transmission and the rest of the junk, then plop that tranny out on Sunday, and stick the new one in on Monday. then track the RocketChip dude down... hopefully he's not too busy LOL...


Does anyone know if it *has* to be a TDI 5 speed, or can I just do the 5th gear mod on another cheaper trans (like $300 less for one on a 2.0 or a 1.8t).

also anyone got a link for the wiring for the backup switch, and VSS, or should I just grab the whole harness while I'm in there?

If you get a 2.0 or 1.8T trans the rack and pinion will be wrong. You'll be running much higher rpms. The 2.6 trans has the same rack and pinion, but the gears are off, so you'll need to put another 5th in, and since the bellhousing is different you'll need to swap that out with a 2.0 bellhousing.
Sound fun?

Dude, there's no way in hell I would take 2k laying down.

I'm sure rack and pinion is a typo...

I'm not taking it lying down, I have done every legal recourse available... lots of options... plus I can put that they suck in my sig... less business for them makes me feel better... like I'm saving others some cash..

Besides, It's not over yet!

Anyone here know if a beatle trans from 98 will bolt up to a 99 golf?

The trans probably will, but I don't know about the mounts. Since its the same platform I would assume that the mounts would be the same.

well, it looks like car-part.com says it's the same... so it's probably correct...

well, there we go. I'll remember that I can get a manual trans from NBs too,

I guess we'll know next weekend... everyone's closed tomorrow and monday here...

I found a 6 speed of of a 2005 1.8T golf. For everything is going to be about $2000. What do you guys think?

Which flywheel should I get?
Which clutch?
The one for the TDI or the 1.8T?

I think you won't have proper gear ratios.... Ifit was that easy all the TDI's here with 6spds wouldn't have got them shipped from Europe.

The 6 speed I'm looking at has a 3.333 final drive and a .912 top gear. which should give me 3,000 RPM at 75 mph (or so)

The five speed has a 3.389 final drive and a .756 top gear. Which gives me about 2600 rpm or so... if I swap with the .681 it drops to about 2300 RPM.

I may still go with the 5 speed, $1,000 less (or so) and a higher top gear = fart-fig-newton!

I decided to put a RPM to MPH calculator on here with gear ratio calculations I think it's correct, It's in XLS format. if anyone has anything to add to the calculations, just ask...

http://www.silenceofthefans.com/tdi/xls/mph.xls

Alpha, give us the transmission code.
The transmissions have two final drive ratios. 1-4 use one, and 5-6 use another.
The 6-speeds popular around here give 2000-2500 at 80 I think.

The two six speed trans I located were EDJ (the lower ratio one, but VR6) and ERR.
The five speed ones I located are EUH, EBJ and DQY

The EDJ shows the overall top gear ratio would be about 2500 RPM (unless I'm calculating it wrong in which case it's 2200 or so)

In any case it's better than my ELY auto trans thats in there right now which runs at 3300 RPM (3500 or so with slip of TC). My car should have come with an ECN or an ELT which would have been a more respectable 2700 (or 3,000 RPM w/ slip).

Of the 5 speeds you want [FONT=Arial, Verdana]DQY, or EBJ.

The 6 speeds' final ratios are:
[/FONT] DRW - 2.10
ERF - 2.12
EFF - 2.19
DRV,FEK,FEL,ERG - 2.34
EUJ - 2.38
ESW - 2.47
EDJ - 2.48
FBS,FEM - 2.51
ERR,FML,FSR - 3.00
DRP - 3.02
ERE - 3.19
EEJ - 3.21

The smaller the better. The ERR would be 50% higher rpms than the DRW.

Got a reference on which cars those were available in?

The DRW would kick some butt... 2,000 RPM at 75

People have reported a 4-6 mpg increase with the DRW. Granted, the whole setup will cost about $3,000 so it won't ever pay ya back.

I just found another 6 speed, It's a FZQ... anyone got the final drive ratio on this one?