Decided to work on swapping the manual pedal assembly over and making the o2x linkage work with the b5.5 box. I pulled the manual b5 shifter box and this pedal assembly from a junkyard earlier this fall when I was gathering parts.
Two boxes side by side. b5 box left 02x box right.
This thread let me know this was possible: https://www.audizine.com/forum/showthread.php/779148-B5-01X-and-02X-Conversion-Thread
Essentially you are just swapping the guts over to the box. Removing the 6mm allens that hold the linkages to the shifter and the t-25 (4) that hold the shifter in the box.
FInal product. o2x linkage and shifter in b5 box.
Got started on installing it in the car. Bolts right up like factory. I love it when things work like this.
After installing plastics you must remove this square plastic piece or the shift boot surround wont click in.
Final product here. I need to find a 6 speed shift knob. An OEM matching wood grain 4motion one would be perfect!
Moved on to pedal assembly. Last time we will be seeing the 2 pedals! Doing this now with the engine out made it much easier when hooking up the clutch line.
Originally I was just going to cut the middle pedal and use the longer pin and add the clutch pedal to the existing pedal assembly like this link showed: https://forums.tdiclub.com/index.php?threads/bhw-01e-6-speed-swap.378108/
However after getting the slave master bolted up to the existing pedal assembly I noticed it didn't have correct spot for the clutch switch. Which meant I needed to swap this whole assembly over. Quite a pain honestly because You have to loosen up the two torx bolts from the engine bay side that holds the brake booster to the pedal assembly. The top one I was able to use an extension and slightly bend down the rain tray, but the bottom one had very minimal access. So i created a access hole. I will use a grommet to plug it up after finishing.
They make these cars very easy to manual swap... Just cutting tip the off the brake reservoir and connecting hose to the clutch master.
3 Pedals are in! I wiil tackle the wiring up of cruise, and safety switch at a later date after I find the correct resources.
Cleaning up the o2x
Cleaned the inside of the bellhousing. It was completely black and installed a new clutch release bearing.
I test fitted the o2x up to the BHW with the pilot bearing installed flush to the flat portion of the BHW crank.
It looks like I have about 1/2" of pilot bearing engagement. Will this be enough?
Tomorrow I will bolt up the Flywheel ,Clutch and PP. Hopefully the BHW starter will work with the 228mm setup.
If not Ill have to find another solution. Maybe a matching o2x starter from a b6 or b7 audi.