Project: 2004 Passat TDI-Manual Swap, BSMD, And More! - Page 3

50mpgtdi · August 14th, 2017, 12:56

Update on the car. I have just short of 1000 miles on it already, and I love it! Mixed driving in town and on country backroads with a little bit of highway driving averages around 35-37 mpg, and the trip I took to Road America this weekend was mostly highway, I got 39.5 on the way up and 41.4 on the way back. It's been running great, rides nice, and everything works just like a factory equipped car. Of course the RPMs are high at highway speeds, ~2900RPM at 75MPH, but as other than that, I couldn't be more happy with it.

Syncrogreg · November 21st, 2017, 13:27

Awesome!

I was wondering if anybody know that FCT trans code. I have 3 trans on the floor 2 DVZ and 1 FCT I just want the one with thetallest ratio for my TDI racecar.

Let me know.

Thanks

Greg

imo000 · November 24th, 2017, 10:26

Quote:

Originally Posted by Syncrogreg

Awesome!
I was wondering if anybody know that FCT trans code. I have 3 trans on the floor 2 DVZ and 1 FCT I just want the one with thetallest ratio for my TDI racecar.
Let me know.
Thanks
Greg

Why don't just mark the axle flange and count the ratio?

50mpgtdi · January 8th, 2018, 14:00

Just wanted to give a little update on this project. I've got 18k miles on it now. Everything had been working pretty flawlessly until today. 3rd gear sync ring broke and jammed in the internal linkage so the trans will only shift into 4th. Does anyone know a good place to order trans parts? Or am I just better off to get another used trans?

vwztips · January 8th, 2018, 17:16

Which gearbox do you have? If FHN or DUK you may want to rebuild as they are hard to come by. Those gearboxes aren't too hard to rebuild. ECS carries those parts. It's funny as Porsche and VW uses the same part #'s but the Porsche parts are usually cheaper

imo000 · January 9th, 2018, 08:08

Get the part numbers and call the dealer. Then you'll know if it's worth fixing it or not.

50mpgtdi · January 10th, 2018, 21:53

I have a DVD from a V6 Passat. I determined it wasn't worth rebuilding when I found one with 142k miles for $100. Haha! Thank you for the info though.

KERMA · January 15th, 2018, 20:28

do you still have the ABS light on? That can easily be fixed with a new OBD tune (no BDM required)

50mpgtdi · February 24th, 2018, 11:54

I do still have the ABS/TCS/CEL on. Could you PM me details about the OBD tune?

On another note, what are people running for transmission fluid? I have Amsoil manual transmission fluid in it, and I'm just not real happy with the shift quality. I used Royal Purple in my 03 jetta, would that also be a good option for this transmission as well?

Uberhare · February 24th, 2018, 16:46

Fuchs 75w80.

Malone Tune

PickleRick · February 25th, 2018, 16:56

I am also using a v6 donor car for my conversion. Its an early 99 model so the brake reservoir will not interchange.

I noticed on my 05 it has a nipple on the bottom of the reservoir, can i just cut that plastic tip off that nipple to use to feed my clutch slave? I cant see any reason not to buy figured i should ask first.

Or do i swap the older brake master cyl?

Or do i just order a later brake/clutch reservoir?

Windex · February 26th, 2018, 07:27

Quote:

Originally Posted by PickleRick

I am also using a v6 donor car for my conversion. Its an early 99 model so the brake reservoir will not interchange.
I noticed on my 05 it has a nipple on the bottom of the reservoir, can i just cut that plastic tip off that nipple to use to feed my clutch slave? I cant see any reason not to buy figured i should ask first.
Or do i swap the older brake master cyl?
Or do i just order a later brake/clutch reservoir?

Just cut the nipple and have it feed the clutch master.

Careful on the feed hose - it's a specific kind of rubber to withstand brake fluid. Expensive at the dealer if I recall

PickleRick · February 27th, 2018, 04:56

Will do. Got her detached from the reservoir but not yet off of the master. My local hose/hydralic shops probably sell brake fluid compatable hose that will fit by the foot but i would rather avoid that route!

So on your engine swap. Ive got a cherry picker engine hoist but may end up borrowing my fathers skid loader to pull the motor. Ive nearly got both motors ready to pull. The v6 is a nightmare compared to the BHW.

It appears i can yank both the engine and transmission at the same time on both cars without touching the subframe. I wanted to verify this before i hook up the chains.

50mpgtdi · February 28th, 2018, 07:15

Uberhare, thanks for the fluid recommendation. Is that the OEM fluid?

I think you can probably do it that way, but I never removed my engine. I left it hanging from an engine support bar while I did my transmission and engine work.

blazen71 · February 28th, 2018, 11:21

https://www.ebay.com/itm/Red-Line-Sy...19.m1438.l2649

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