50mpgtdi
Well-known member
I've been a member on the forums here for quite a few years, but have been largely inactive due to having sold my 03 Jetta TDI a while back. But now I've rejoined the TDI community and I'm very excited to be back! I recently picked up a 2004 Passat TDI with 126k miles. Overall it seems to be a great base to start with. It's pretty clean with the exception of some light front damage from hitting a small deer, which will be repaired after all of the mechanical repairs and upgrades are completed. I picked it up to the tune of $800. Reason being, the transmission is giving some problems. When I got it, it would drive in reverse, but it acted like it was stuck in two gears when trying to go forwards. After reading the codes, I cleared them and now it will drive forwards. However, it shifts ok through 1st and 2nd, but it acts like it goes into neutral when it shifts to 3rd, then tries to slam into 3rd and fails. Rather than chase after the nonsense of diagnosing and repairing the auto trans, I am opting for a manual swap. I know the method I am taking about the manual swap will be frowned upon by some here, but it fits my budget and I think I will be satisfied with the end results. If not, I have the option to change things later. Rather than import components from a Euro TDI, I purchased a donor car to source my parts. It is a 2001 Passat V6 5-speed with 193k miles. This way I have most everything I need to complete the swap, and I only paid $300 for a running and driving car. I will be going with Malone Stage 2 Tuning and the Manual Swap tune. And I will be going with a single mass flywheel and heavy duty clutch for a 1.8T Passat. As for the BSM, there is no record of it or timing belt having been done, so I am doing a BSMD and timing belt kit as preventative maintenance to protect my investment. Beyond the mechanical spectrum, I will be repairing the light front end damage, and making some interior upgrades. For the interior, assuming components will work from the donor car (can anyone verify or deny that interior parts will work between B5 and B5.5 cars?) I will be removing the grey cloth interior and installing the black leather/wood grain interior from the donor car. Later down the road, I will upgrade to a nice set of wheels and possibly some mild suspension work. Overall I am very excited to get started and get this beast on the road! Thank you in advance to everyone who has posted in the past about your repairs and modifications, I and others here greatly appreciate your experience and knowledge! I will add pictures along the way as I get started!