02 Allroad BHW swap w/ euro TDI 6MT

Scott02

Veteran Member
Joined
Jan 17, 2006
Location
near Youngstown, OH
TDI
Too Many


The Basics:

  • 2002 Audi Allroad (originally a 2.7biturbo auto)
  • Atlas Grey
  • Dark grey roof (matches the grey on the plastics)
  • ~181k miles on the chassis
  • Two tone heated leather seats front and rear
  • Rare 3rd row seating
Exterior additions:
  • Roof cross bars - several different brands/styles
  • Shorty antenna (clearance for long items like kayaks on roof)
  • 3300lbs rated trailer hitch - allroadhitch AT gmail DOT com
  • NEEDED: Evolution Alum Skid plate
  • NEEDED: HID headlights
Engine and Mods:
  • 150kmi BHW Engine pulled from a wrecked 05 Passat sedan
  • Stock Injectors
  • Stock gt1749va turbo
  • Stock Cam (not worn at all)
  • TDTuning Tune
  • Mods @ 181kmi/150kmi (Jan 2014)
    • New Steel Glowplugs
    • New timing belt and water pump kit
    • BSM Delete
    • EGR Cooler Delete
    • 2.5" Downpipe/Exhaust
Drivetrain and Mods:
  • Euro TDI 01E 6spd manual quattro transmission - Dutch Auto Parts
    • FTL code (find 1-6 ratios)
    • 3.889 final drive
  • Custom 01E clutch - Whitbread Performance
  • Rear end
    • EUT code - 3.889 ratio
  • Mods @ 181kmi/150kmi (Jan 2014)
    • Trans - New fluid, new axle seals, and out flange seal
    • Rear end - New fluid and new axle seals
Interior:
  • Allroad badged rubber mats
  • NEED: Gauges or Torque App
Rims & Suspension:
  • 17" stock 5 spoke rims with new Dunlop tires
  • Various other rim/tire sets for winter or a change of pace
  • Correctly operating stock air suspension
  • 8 pad HP2 dual piston front brakes
  • non-vented rear rotors (this will probably change)
Body Condition:
  • One small ding that caused the paint to crack on the passenger front door.
  • A few other very minor scratches here and there.
  • That's it! Super clean.
Issues:
  • Needs me to completely finish the swap!
Maintenance:

  • ...
 
Last edited:

burpod

teh stallionz!!1
Joined
Nov 27, 2004
Location
cape cod, ma
TDI
82 rabbit vnt ahu, 98 jetta vnt ahu, 05 parts car, 88 scirocco.. :/
nice.... the perfect wagon to do a REAL swap with :) i'm jealous
 

Dirty_Al

Active member
Joined
Mar 13, 2005
Location
Tucson, AZ
TDI
Jetta Wagon, 2002, Blue
Great thread...Looks very similar to mine except for the ALH instead of the BHW and the 3rd row seating is pretty sweet!
 

PassatTDIesel

Veteran Member
Joined
Jan 9, 2005
Location
Sherwood Park, Alberta, Canada
TDI
Passat 05 TDI Silverstone
How is it coming along?
Thinking about doing the same swap.
Found a 02 AR with a blown transmission for $1500.
Figure I could sell the 2.7T and break even on the vehicle.
My 05 passat bhw has around 325K on it. The car is getting tired and TC is starting to go.
Looking for a new project so was thinking along the same lines as you.
Good luck with everything and keep us posted on your progress.
For whatever reason, none of your pictures are showing up in your posts. Could just be me but I've tried on 3 computers so far.
 
Last edited:

Scott02

Veteran Member
Joined
Jan 17, 2006
Location
near Youngstown, OH
TDI
Too Many
How is it coming along?
With the VERY cold weather, life, work, etc., it's (unfortunately) going way too slowly.
How's the allroad tdi coming along? Any major hurdles yet? What is your expectation on power for the upgrades you intend to do on the bhw?
Power will be just a tune for the first "while".
Long term goal is either Race or Whitbread nozzles, either gtb1756vk or gtb2056vl turbo, and a cam regrind (before mine, that looks great, trashes itself).

What ratio 01E did you go with?
I have the 1-6 ratios on my work computer, I will update them when I can.
The trans code is an FTL with the 3.889 final drive ratio.
I updated, and will continue to update my original posts with the details of the build.

And SOMEDAY, I'll make a build thread in the conversions section. This thread's intent was a picture and mod list of the project.
 
Last edited:

Windex

Top Post Dawg
Joined
Apr 1, 2006
Location
Cambridge
TDI
05 B5V 01E FRF
I found the ratios - .56 6th. Same as the 01e FRF I'm using.

Have you selected a clutch/flywheel yet?
 

Scott02

Veteran Member
Joined
Jan 17, 2006
Location
near Youngstown, OH
TDI
Too Many
Absolute zero progress has been made. The allroad is good and well nestled in the back garage.

I find myself working on other shorter term projects like my beater 00 Jetta (that will soon be for sale), my newly acquired 03 Jwagon, and my father's cummins megacab.
Pretty much all of those needed all the drivetrain wear items replaced all at the same time. Good times.
 

GASDAG

Veteran Member
Joined
Feb 2, 2013
Location
Columbus, OH
TDI
2002 Jetta GLS 5MT Sedan Silver, 2004 GMC Sierra i.e. no need for a wagon
Subscribed for fellow buckeye doing the ultimate swap. Can't believe you're going to have a quattro 6 speed tdi in the end... Would like to see progress brotha!!!
 

Scott02

Veteran Member
Joined
Jan 17, 2006
Location
near Youngstown, OH
TDI
Too Many
Unfortunately, since April, zero progress has been made.

I have some parts arriving soon. So, that should jump start my desire/priorities back towards working on her.
 
Top