Thought I’d document a manual swap on the 1.8T for the B5/B5.5 folks. This pertains specifically to the B5.5, but the B5 and V6 is similar.
I couldn’t have undertaken this project without the help of the many resources in the Audi Forums below. I will also be taking snippets from them for this to put it all in one place.
Biketsai's DIY Auto-to-Manual Conversion
YET another 5-speed swap - in progress
Many, many thanks to vwb5t for the help and knowledge on pulling it all apart and putting it back together.
Items needed/should replace:
- Auto transmission mounts
- Auto trans bracket for pass side of transmission
- Brake and clutch pedal with spring, clutch master retention pin, long pin and pin clips. (or whole assembly)
- Clutch switch and at least 4-6” of its wiring pigtail (for cruise control and other items later explained)
- Starter interrupt clutch switch with wiring(shows pedal pushed in for start; not required, but good to have)
- Audi/VW 5 Speed manual trans 01A
- Reverse switch wiring pigtail from donor car
- clutch pilot bearing 15x24x26mm # 034105313A
- New clutch (I went with the Valeo SMFW conversion)
- New clutch master cylinder
- New clutch slave cylinder
- Manual axles for your year of Passat
- New Axle bolts, inner flange and outer
- Manual trans downpipe and associated gaskets
- Shifter assembly and linkage
- Clutch hard line from master cylinder to slave (or braided line if you can get it)
- New Flywheel bolts (these are tq to yield)
- Two Feet of 5/16th Vac Hose for pedal-brake reservoir line
- Engine Rear main seal (mine was completely dry and perfect at 155k)
Tools:
- Transmission Jack
- 2' Jack stands
- Jack
- 12pt. triple square bolt set for the CV axles
- 17mm 12pt. socket for automatic flywheel bolts
- T45 Torx socket to remove brake reservoir/thing behind it to access room for the clutch hardline
- T55 Torx for Torque Converter
- Torx Bit set
- Clutch alignment tool (comes with clutch)
- $25 17mm Allen/12pt Drain
- Various sockets, extensions, allens, wrenches
- Impact wrench, air ratchet
- Torque wrench
- Angle Grinder (depending on the pilot bearing)
- Power bleeder (not necessary)
- Drain pan
Fluid/materials:
- Brake fluid DOT3/4
- Blue Loctite
- Brake cleaner
- Lots of rags
- New trans oil (75w80)
Software/coding changes:
- Recode ECU to Manual (you will get error codes and possibly erratic behavior)
- Recode ABS module to manual
- Throttle Body Alignment
Let’s start
You will need enough mechanical knowledge to remove and reinstall the two transmissions. The removal will be a high level overview.
Auto Transmission removal
- DISCONNECT BATTERY. This cannot be stressed enough.
- Remove the axles
- Remove downpipe, either detaching cat converter from turbo or pipe from converter. We found it easier to remove both together from the top, but required cutting the downpipe just ahead of the flex joint. My flex was shot anyway.Remove starter, tuck wires out of the way
- Disconnect trans wiring.
- Remove tq converter bolts from flexplate through the starter opening. Turning engine clockwise with the front crank bolt to line up each time.
- Remove bellhousing bolts
- Undo the transmission lines from radiator and detach mounting bracket
- Support with trans jack and remove the mounts. For easier maneuvering, Remove the brackets from the trans as well.
- Have fun removing the beast. Tq converter may get stuck and separate from the trans causing fluid to go everywhere. Ask me how I know.
