Converted auto to 6sp manual in Jetta TDI wagon

[halfmill]

I did a conversion on my 2003 Jetta, TDI wagon using a 6 speed kit from Ryan. Everything works well and engine light is off but....I can't pass NYS inspection because I still get 10 faults from TCM even thought the ecu has been modified with Ross Tech Vag to show the car is a standard trans. Has anyone done this successfully?

 

[SFHGolfTDI]

Maybe you should contact RyanP or one of the tuners to see if they have a solution. It doesn't sound like it should do that if everything was set up correctly. Or ask some of the guys who've done it before if they have any suggestions: http://forums.tdiclub.com/showthread.php?t=305287

 

[halfmill]

contacted Ryan and he said he's never done a US car. I've searched everywhere and everyone says to do what I've done but nobody mentions the fact that the TCM is still being used and the DTC are still listed under MOD 7, the car won't pass readiness test for Comprehensive components. The link you show is for a manual 5speed to a 6speed. I can't seem to find anyone that's done an auto to manual and passed NYS emissions?

 

[SFHGolfTDI]

Well probably hundreds have done auto to 5-speed. Would that cause the same problems you are having with the 6-speed?

 

[halfmill]

I'm assuming so.It's not a problem unless you have to pass emmisions, even with engine light off the NYS coder will read that there are 10 faults for transmission that is no longer in the car. They are now considered emission problems.

 

[SFHGolfTDI]

Have you driven enough for the readiness to reset on all your different modules after the swap? It can take a while.

 

[halfmill]

The Car was due for inspection Feb of 2015, I did the update last spring after the inspection was done, say April 2014. Yes there has been enough time. I have reprogrammed the end digit codes that are requested many times and I can never get rid of DTC for auto trans. Some people have mentioned unplugging TCM but it's still being used for reverse lights and cruse control etc... which all works. Remember a standard car to begin with does not have a TCM, my car does.

 

[SFHGolfTDI]

The Car was due for inspection Feb of 2015, I did the update last spring after the inspection was done, say April 2014. Yes there has been enough time. I have reprogrammed the end digit codes that are requested many times and I can never get rid of DTC for auto trans. Some people have mentioned unplugging TCM but it's still being used for reverse lights and cruse control etc... which all works. Remember a standard car to begin with does not have a TCM, my car does.

If a standard car doesn't have it, why do you need it for reverse and cruise? This just can't be that big of an issue. I would contact some of the people who have pioneered these swaps and ask for help. Maybe they can scan their own cars and see if they have the same readiness problem you do.

 

[dogdots]

Just remove the TCM like the rest of us have done

 

[SFHGolfTDI]

Just remove the TCM like the rest of us have done

Well, there you go. Here's a full write up: http://forums.tdiclub.com/showthread.php?t=151516

Good luck.

 

[SFHGolfTDI]

So, looks like delete the TCU/TCM, and then you might need to play around with VCDS a little more to get everything clear: http://forums.tdiclub.com/showpost.php?p=4755420&postcount=2344

 

[halfmill]

I will look at the links suggested tonight (at work now) but I hope someone shows what to rewire after the TCM has been unplugged. I used the directions from Boerje (PDF) that Ryan suggested with his kit. Thanks hope it works.

 

[SFHGolfTDI]

I found some more specific info for you in the same thread. Look around http://forums.tdiclub.com/showpost.php?p=4800815&postcount=2356

You are not alone in the problem.

 

[SFHGolfTDI]

I will look at the links suggested tonight (at work now) but I hope someone shows what to rewire after the TCM has been unplugged. I used the directions from Boerje (PDF) that Ryan suggested with his kit. Thanks hope it works.

Why would you need to rewire anything? A TCM is not necessary for a manual car, so once you code it right, delete the TCM, and reset readiness you should be able to have everything working.

 

[chudzikb]

Or you sell it to one of us in PA where there is NO emissions for diesels and call it a day! Just saying...

 

[selway]

I did a 5 speed swap and had the 10 transmission codes you had was 3 months to get rid of the dtcs the reason was all I had to do is disconnect the tmc and what do you know no check engine light everything works .Ask ? s on here for 3 months no help as for the instructions on the 5 speed swap it did not say to disconnect the tcm wish it would of . That was my only problem with the swap .forgot to mention the 10 codes all came up on the ross tech cable for 3 months after each scan no check engine light but after disconnecting the tmc no codes came on the scan .

 

[boertje]

I will look at the links suggested tonight (at work now) but I hope someone shows what to rewire after the TCM has been unplugged. I used the directions from Boerje (PDF) that Ryan suggested with his kit. Thanks hope it works.

Did you get your issue resolved?

Why would you need to rewire anything? A TCM is not necessary for a manual car, so once you code it right, delete the TCM, and reset readiness you should be able to have everything working.

Rewiring is needed to have a functional cruise control, reverse lights, and start safety circuit as the manual cars have and swap out the 175 relay that the auto uses in favor of the 53 relay the manual uses when TCU is removed. Recode the ecu to keep it from looking for the TCU to eliminate codes and also physical removal of the TCU to keep it from triggering codes. See section 7 and 8 in the how to linked in my sig. Can-bus MAY need to be reset in some cases on YM 2002 and newer to completely eliminate transmission errors.
All my auto to manual swaps show "ready" on all respects when these instructions are followed.

I did a 5 speed swap and had the 10 transmission codes you had was 3 months to get rid of the dtcs the reason was all I had to do is disconnect the tmc and what do you know no check engine light everything works .Ask ? s on here for 3 months no help as for the instructions on the 5 speed swap it did not say to disconnect the tcm wish it would of . That was my only problem with the swap .forgot to mention the 10 codes all came up on the ross tech cable for 3 months after each scan no check engine light but after disconnecting the tmc no codes came on the scan .

Curious what instructions did you use?

 

[SFHGolfTDI]

Boertje, I was under the impression the op followed your how-to but it doesn't sound like he did if all the information was there about tcm, wiring and vcds.

 

[boertje]

Yeah that could be and it does say to remove the TCU. I remember the first one I did, I swore after I would never do another. After reading the original thread, I was more confused about wiring than ever, thus the reason for that howto. It can be a daunting task. Now, I find it all easy.

 

[halfmill]

Your option of me selling the car sounds the easiest way so far.

 

[boertje]

Yeah, but that is no fun especially after you put all that work into it.

 

[halfmill]

Thanks for the help. Boertje your directions were correct I read it as just removing the TCM connector to do mods instead of physically removing TCM. Anyway I've been travelling all week and will tackle it this long weekend.

 

[boertje]

Cool, let us know how it works out.

 

[halfmill]

This morning I unplugged the TCM and car wouldn't start unless it was plugged in? I know all wiring was done correctly because my reverse lights and cruse controlled has worked for last 8 months I drove the car as a 6speed. I noted that I had no glow plug light with TCM unplugged??

 

[BobnOH]

I think there are some few wires connected thru the TCU that need moved to the ECU.
Hopefully, you've done the wiring yourself and can track these down. If someone else wired it, it will be a puzzle.

 

[halfmill]

I have triple checked all wiring according to Boertje pdf directions, the only thing that was screwed up was the TCM being plugged in. Like I said I drove this for 8 months and everything worked (cruse, reverse lights etc..).I'm thinking I need to unplug it, re-hookup battery, turn key on and reset the softcodes and clear dtc if any. Hope that works cause I'm really getting tired of working on this car!

 

[boertje]

Did you replace the 175 relay with a 53 relay and do the wiring under the dash on the 175 relay's plug and double check pin out? Did you do the minor wiring change in the TCU's old plug connecting yellow/blue to yellow/red wire and go to pin 19 on ECU plug moving that yellow/red wire to pin 66 (empty slot)?
Something doesn't line up.

 

[selway]

I used your instructions but I do see it says to remove the tmc must of had a brain fart , anyway thanks for the write up no more auto enjoying 49 to 52 on the highway thanks for the great write up .

 

[boertje]

Thank you sir! I know I have not regretted dumping the auto. Don't like its mileage penalty.