BHW/01E 6 Speed Swap

MILESB

Veteran Member
Joined
Jul 30, 2007
Location
alberta
TDI
03 Jetta, 04 Passat Wagon
I'm considering selling my 6 speed wagon complete and AWD parts as a package deal:

Body is rusty - but mechanically very good. Runs and drives except for a broken front spring.
BHW w/350K kms (stock BSM)
Malone Tuned ECU for 6 speed
01E 6 Speed (GVS)
Car has stock DMF 240mm installed currently
New in box: LUK DMF & Sachs SRE clutch kit
01E AWD trans (GLX / 3.89 R&P)
Matching rear diff from W8 Auto (3.89 R&P)


Send me a PM if you are serious. Only offering as a complete package.

Optional: 2003 Passat W8 Wagon - runs & drives, needs fenders/hood/windshield
Hello, would you happen to know the part numbers for the front axles or half shafts, if they’l work in a front wheel drive 6 speed?
Thanks
 

sword_guy

Member
Joined
Oct 30, 2017
Location
NECT
TDI
2004.5 2.0L Passat Wagon
I have some questions about your 6 Speed swap, if you don't mind. I asked Dutch Auto about a 6 speed and they said the DMF won't work unless I change my crankshaft. What does he mean? I also heard the SMF will cause the transmission to damage itself. Is there a mod so that the DMF can be used? If it's covered somewhere in the forum thread, I can't find it. Can the final drive gears be changed on those transmissions? Also, does the parts list in the post include everything you ended up needing for the swap? Wondering which axles you ended up using. Thanks a lot if you can answer this stuff!
 

Uberhare

Veteran Member
Joined
Sep 3, 2006
Location
Ontario, Canada
TDI
Too many.
The difference is the length of the crankshaft where the pilot bearing goes in. It's covered about 10 pages back. You can get away with the stock BHW crank. Just don't drive the bearing all the way in.
 

sword_guy

Member
Joined
Oct 30, 2017
Location
NECT
TDI
2004.5 2.0L Passat Wagon
Thank you. I wondered if that was it. Nice to know it's that simple. Do you have part numbers for the driveshafts? Or a vehicle they would have come from? Apologies if that was also covered. I tried my best to read through the whole post.
 

Uberhare

Veteran Member
Joined
Sep 3, 2006
Location
Ontario, Canada
TDI
Too many.
The axles came from the same vehicle as the trans. Sorry don't have the part numbers handy. You can change the flanges on the trans and use the smaller diameter shafts that are more readily available here. I think someone on here has the part number for the flanges? I never looked into it myself.
 

sword_guy

Member
Joined
Oct 30, 2017
Location
NECT
TDI
2004.5 2.0L Passat Wagon
That's ok. Thanks for replying. That only leaves the last question. Are the final drive gears changeable on these? I want to get really tall gearing. Having a tough time finding reliable gear ratio data.
 

Windex

Top Post Dawg
Joined
Apr 1, 2006
Location
Cambridge
TDI
05 B5V 01E FRF
No, no aftermarket gears available for the O1E. If you get a dqs or frf from a V6 tdi, it will have the tallest gearing available in a fwd 01E gearbox
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
That's ok. Thanks for replying. That only leaves the last question. Are the final drive gears changeable on these? I want to get really tall gearing. Having a tough time finding reliable gear ratio data.
Why do you want that?
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI
Why do you want that?
Land speed record attempt? Or maybe trying to push the BSFC out the bottom of the curve to burn more fuel?

Realistically, 2000 to 2500rpm range is ideal for best economy, lower the rpm, it gets worse. Raise it, it gets worse.
 

sword_guy

Member
Joined
Oct 30, 2017
Location
NECT
TDI
2004.5 2.0L Passat Wagon
Land speed record attempt? Or maybe trying to push the BSFC out the bottom of the curve to burn more fuel?

Realistically, 2000 to 2500rpm range is ideal for best economy, lower the rpm, it gets worse. Raise it, it gets worse.



You caught me. Definitely land speed record. Seriously though, fuel economy is greatly dependent on load. At extremely low loading (level ground), it's more efficient to run at a lower RPM. I ran some tests. We have a dam nearby that's about half a mile long and level. My car will allow a shift at 41 mph (indicated), but it will not automatically shift until 45. I set cruise at 41 and observed instantaneous fuel economy. Forced the shift into 5th and economy went up by roughly 12mpg. There are times when a low RPM is better. Taller gearing with a 6 speed would allow the ability to adjust accordingly.


For the V6 transmissions you mentioned, I was under the impression that they would not bolt up to the 4cyl engine. Is that not the case?
 

QuickTD

Veteran Member
Joined
Feb 25, 2002
Location
SW Ontario
TDI
2003 Audi A4Q 5spd 2.0 TDI 2056VK R783, 2006 Audi A4Q 6spd 2.0 TDI
For the V6 transmissions you mentioned, I was under the impression that they would not bolt up to the 4cyl engine. Is that not the case?
All of the VW/Audi longitudinal manual transaxles have a dual bolt pattern and will fit any VW watercooled engine, 4,5, 6 or 8 cylinder. The flywheels are different but the bellhousings are all the same.
 

Windex

Top Post Dawg
Joined
Apr 1, 2006
Location
Cambridge
TDI
05 B5V 01E FRF
You caught me. Definitely land speed record. Seriously though, fuel economy is greatly dependent on load. At extremely low loading (level ground), it's more efficient to run at a lower RPM. I ran some tests. We have a dam nearby that's about half a mile long and level. My car will allow a shift at 41 mph (indicated), but it will not automatically shift until 45. I set cruise at 41 and observed instantaneous fuel economy. Forced the shift into 5th and economy went up by roughly 12mpg. There are times when a low RPM is better. Taller gearing with a 6 speed would allow the ability to adjust accordingly.


For the V6 transmissions you mentioned, I was under the impression that they would not bolt up to the 4cyl engine. Is that not the case?
The 6 cyl tdi transmission will indeed bolt up to the 4 cyl tdi engine. The bolt pattern is the same at the 4 cyl 01E transmission.

If you need any more convincing that it will fit, I can send you pictures of the FRF 6 cyl 6 speed that has been in my car for the last 200k miles.
 

MILESB

Veteran Member
Joined
Jul 30, 2007
Location
alberta
TDI
03 Jetta, 04 Passat Wagon
6 speed gearbox mounting bracket

I’m still piecing together all the parts for my DQS 6 speed conversion project. I’m hoping that someone knows the part numbers for the left and right of gearbox mounts? Also, the part number for the pillows between those and car body? And Is there a part number for the piece of sheet metal that is between bell housing and motor? Not the 5.5 spacer.
 
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imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
Just look for a B5 or B5.5 gas V6 manual transmission, driver side transmission mount bracket and you will get the correct part number. The passenger side transmission mount bracket is the same as the one you already have with the automatic transmission. As for the rubber transmission mounts/pillows, they are the same as the automatic transmission you already have.
 

vwztips

Veteran Member
Joined
Aug 30, 2009
Location
Greenville, SC
TDI
2005 Passat GLS Wagon TDI 5 spd manual w/BSM delete 2012 Tiguan TDI/DSG 2004 Audi TT R-line Conv 2011 BMW X5 35d
Just look for a B5 or B5.5 gas V6 manual transmission, driver side transmission mount bracket and you will get the correct part number. The passenger side transmission mount bracket is the same as the one you already have with the automatic transmission. As for the rubber transmission mounts/pillows, they are the same as the automatic transmission you already have.
Are you saying that you can use the passenger side transmission bracket is the same for an auto and manual? If so, that is not correct. The auto is much wider than a manual and uses different brackets.

The passenger side mount from a manual car is the same for V6 or 1.8t. The driver side needs the V6 mount if you are keeping the TDI sub frame. If you swap the TDI subframe with 1.8t manual subframe, then you can use the transmission mount from a 1.8t manual
 

imo000

Top Post Dawg
Joined
Dec 13, 2005
Location
Cambridge
TDI
2009 M-B ML320 Diesel & '05 Passat TDI Manual 5-Speed
I don't remember buying a passenger side transmission mount whey I did my swap. But that was 5 years and several car project ago so my memory could be off.
 

Daen00

New member
Joined
Sep 3, 2020
Location
Avon
TDI
B 5.5
The 6 cyl tdi transmission will indeed bolt up to the 4 cyl tdi engine. The bolt pattern is the same at the 4 cyl 01E transmission.

If you need any more convincing that it will fit, I can send you pictures of the FRF 6 cyl 6 speed that has been in my car for the last 200k miles.
Do i need that platw between trany and engine?
 

GoremanX

Veteran Member
Joined
Mar 17, 2013
Location
Vermont
TDI
2001 Audi A4 Avant quattro w/BHW TDI & 01E 6-speed
Do i need that platw between trany and engine?
That's determined by your choice of clutch and flywheel, not by the engine/transmission. A 240mm clutch will typically need a spacer. An 01E very much prefers a DMF, rather than a SMF and spring clutch disc, which combined with a 240mm clutch means you need the spacer to prevent the clutch from running against the bellhousing
 

Daen00

New member
Joined
Sep 3, 2020
Location
Avon
TDI
B 5.5
That's determined by your choice of clutch and flywheel, not by the engine/transmission. A 240mm clutch will typically need a spacer. An 01E very much prefers a DMF, rather than a SMF and spring clutch disc, which combined with a 240mm clutch means you need the spacer to prevent the clutch from running against the bellhousing
Thanks.....cause is hard to find a spacer......
 

Scott_DeWitt

Vendor
Joined
Apr 7, 2004
Location
Texas USA
TDI
2000 Audi A4 1.9TDI quattro
All of the VW/Audi longitudinal manual transaxles have a dual bolt pattern and will fit any VW watercooled engine, 4,5, 6 or 8 cylinder.
This isn't true, after 2002. later engines have bolt patterns that have different bolting patterns.
 

yahmon

Veteran Member
Joined
Dec 27, 2012
Location
canada
TDI
04 passat tdi 6spd stage2 webasto TC3 , 04 passatW8 6 spd, 10 Jetta TDI 6spd stage 1
That spacer from audi s4 2004 is the same?
This is the correct part number i believe, 01E103551B easy to find in europe got it here for less then $50Cdn
 

yahmon

Veteran Member
Joined
Dec 27, 2012
Location
canada
TDI
04 passat tdi 6spd stage2 webasto TC3 , 04 passatW8 6 spd, 10 Jetta TDI 6spd stage 1
Can/Gateway: Set coding to 006. Same as before but it will force the gateway to relearn installed modules.

ABS - Recode:
Login to enable coding 09555
Recode to 04255
NOW perform steering angle sensor calibration. (Failure to compelete this will cause the coding not to complete.) Login to enable Basic Settings (40168)
Perform G85 calibration in Basic Settings group 001
[/QUOTE]

Before all this you need to change engine soft code to 0150032 or 0150031. It fixes most communication errors
 

MILESB

Veteran Member
Joined
Jul 30, 2007
Location
alberta
TDI
03 Jetta, 04 Passat Wagon
Rear main seal was just starting to leak, so I replaced it:


Installing the clutch line. This was the worst part of the install, and you'll want to do this with the trans out. ELSA tells you to remove the brake booster. The lower torx bolt is a PITA. Some have been able to bend the line slightly to get it to fit. I didn't want to force it through, so I loosed the booster and pulled it forward an inch. Un-thread the bolts almost all the way - they are pretty long. Clutch line position from underneath:


I reused all the original grommets, just poked a hole in them for the lines to go through.

New dowel pins: (old one in the pic for comparison)


Side by side comparison for size (I can actually pickup the 6 speed by myself!):



Old starter and new starter (now go sell yours to someone else!):

You will have to remove the turbo support bracket. I am looking into finding a different one that fits, or fabricating something. I also had to unbolt the a/c compressor to get the starter in. Yes - it's that big... :)



Fits like a glove:


They left an access hole in the driver's side mount to tighten the bolt....
Hello, what did you end up doing with the turbo support? I finally got all the pieces together and we’re currently intalling a DQS with the 240 clutch into my 2004 Passat but the starter and the turbo support don’t like each other.
 
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