vwztips
Veteran Member
- Joined
- Aug 30, 2009
- Location
- Greenville, SC
- TDI
- 2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2011 Tiguan TDI/DSG 2005 Audi A4 Avant 6MQ TDI 2011 BMW X5 35d
Well I picked up a 2004 B5.5 with a bad tranny and decided to convert it to a manual. I removed the complete engine and tranny and installed a BSM while it was out. Also inspected the cam, bearings and lifters. Cam was within specs but the lifters had some wear so I decided to replace the lifters and cam bearings.
As for the tranny, I found a donor V6 car with all the necessary parts. I have performed a lot of calculations for various VW trannys and found the optimum one in Europe. So before ordering one from Europe, installing it and being less than pleased with the results, I installed the DVZ 5 speed tranny from the V6 gasser. As expected from my prior calculations the ratios are not what I want but it helps get all my bugs out first.
Several steps were just a royal pain but nothing patience and lack of sleep could not over come.
3-26-12 update
I received my tranny from Europe and installed it along with a SMF Valeo clutch. Have been working with Mike at TDTuning to get the Stage 2 tune dialed in with no lights or codes thrown. Car runs great and is a blast to drive. Have put over 1500 miles on the car since the swap and have avg 33 MPG or above around town. 40+ on hwy but have not had too many trips yet.
Here are some (poor) pics of the manual shifter. One note about the shifter is that I had one on the shelf with clear coat/stain cracked and peeling off. I removed the rest of it, stained the wood underneath and put 4 coats of polyurethane on it. $5 of materials vs dealer cost of $300+ for a shift knob!
Also had gauge set leftover from one of my 1.8t cars and installed them as well.
As for the tranny, I found a donor V6 car with all the necessary parts. I have performed a lot of calculations for various VW trannys and found the optimum one in Europe. So before ordering one from Europe, installing it and being less than pleased with the results, I installed the DVZ 5 speed tranny from the V6 gasser. As expected from my prior calculations the ratios are not what I want but it helps get all my bugs out first.
Several steps were just a royal pain but nothing patience and lack of sleep could not over come.
3-26-12 update
I received my tranny from Europe and installed it along with a SMF Valeo clutch. Have been working with Mike at TDTuning to get the Stage 2 tune dialed in with no lights or codes thrown. Car runs great and is a blast to drive. Have put over 1500 miles on the car since the swap and have avg 33 MPG or above around town. 40+ on hwy but have not had too many trips yet.
Here are some (poor) pics of the manual shifter. One note about the shifter is that I had one on the shelf with clear coat/stain cracked and peeling off. I removed the rest of it, stained the wood underneath and put 4 coats of polyurethane on it. $5 of materials vs dealer cost of $300+ for a shift knob!
Also had gauge set leftover from one of my 1.8t cars and installed them as well.


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