Certified Volkswagen Nut
- Jul 10, 2006
- Tacoma 4x4 converted to TDI
thanks! but i feel like a dope for not running this down sooner... i need to pay more attention to the label file next timeNice, good work!
this is my FIRST B5.5 swap and i feel like every pitfall that existed i fell into... is the 5.3 procedure wildly divergent from the 5.7?Good to know. I have done over 30 conversions and had not seen that error before.
FWIW there is a different procedure if you have a Bosch 5.3 ABS
Is this necessary at all?
I’m looking over the shopping list and I could use the part numbers for the starter and the 6 speed shifter & rods, pleaseFirst - thanks to all who have written info on this in previous threads.
Second - I am half way though my swap and have discovered a few things not previously mentioned.
Let's start with the REAL parts list: (Work in progress will update as I complete my swap.)
6 Speed transmission
Passenger side heat shield above axle
240mm flywheel/clutch (get new bolts if reusing used parts)
Pilot bearing 056105313C
6 speed shifter & rods, boot and knob.
Axles. (larger inner CV than 5 speed units)
5.5mm spacer plate between bellhousing and transmission 01E 103 551B if using stock 240mm DMF. 228mm can do without.
*** 16x18.8 dowel pins x 2. 01E 301 153E. No one has mentioned this before!
Clutch switches and pigtails.
Clutch pedal with longer mounting pin
Brake pedal and rubber - OR cut and modify your original one.
Clutch master cyl, slave cyl and line. Apparently one from a NA 1.8T will work fine
Longer upper starter bolt
Longer bolt + nut for passenger side lower through block
Also used a bolt + nut to relocate the starter wire support on the passenger side. There is an extra through hole up there not used.
Fresh gear oil (recommended)
New outer CV boots (recommended)
In the beginning.........We had a funny looking brake pedal, and something was missing.
In this image you can see where the master bolts in above the steering shaft. There are two grommets you will pull out. Push them through to the engine side. Bolt up the master without the pedal attached. It sticks through the firewall far enough to clip in the line after. Then put the pedal in. It's a tight squeeze, but just fits between the fuse panel and the steering shaft. Just rotate it around, it goes.
Here's how I dealt with the brake pedal, as I didn't get a donor one:
The all important 3 pedal shot:
I chose the perfect timing to do my swap. There was a vibration in the front right, which I had assumed was from a torn CV boot eating up the outer joint. WRONG:
Here you will notice 2 bolts missing. The other 4 also were well on their way out. Car was dealer service prior to my purchase.....
More updates to come....
GoremanX, I looked through your past posts but couldn't find direct info on this since it looks like you tried a handful of different clutch setups before finding one that worked well.Depends, I guess. If you want to run a 240mm clutch and dual mass flywheel, then you need a 5mm spacer between the engine and transmission, which can reduce engagement in the pilot bearing to less than 3mm (not nearly enough). This solution would resolve that issue. In my case, I'm running a 228mm clutch and dual mass flywheel, so I don't need a spacer. That means my pilot bearing gets plenty of engagement. I recently inspected it after 2.5 years and 35k hard miles, and it's in perfect shape.
oops, missed this until now.GoremanX, I looked through your past posts but couldn't find direct info on this since it looks like you tried a handful of different clutch setups before finding one that worked well.
Which 228mm DMF and clutch are you running now? Happy with it?
I was looking for a 6 speed shifter assembly for my conversion and I spotted a one but it’s saying it’s for 2002 b5 Passat, does anyone know if it’s compatible with a 2004 b5.5 Passat?
In that case, good luck. Those are getting increasingly difficult to find used. The shifter, base and plastic housing are relatively easy to find since they were essentially the same on the B5 A4/S4 and C5 A6/S6/allroad. The rods however differ by model, and even by year within a model. You're specifically looking for the 6-speed setup from a B5 S4 or C5 A6/allroad that had the 2.7 biturbo V6. The shift selector rod and the cross rod can vary depending on whether your transmission uses the "early" or "late" style mounting for the cross rod. Check the JH Motorsports site for info on the B5 S4 shifter, they have pictures showing the differences. There's also a rare, undocumented 3rd setup with the cross-rod attached to the top middle of the transmission. My own 01E came from a later model C5 A6 (euro TDI model), but has both the "early" and "late" style mounting holes, and I was able to find an S4 "early" style shift selector rod assembly on eBay that works fine. I also upgraded to the JHM HD cross-rod, solid short throw shifter, solid selector bushing, stiffer centering spring, and weighted selector arm. Only reason I remember all this is because I just rebuilt that transmission from scratch a couple weeks agoB5 S4 is the only 6 speed shifter in NA that will work.