First thing to find out is if the auto and manual gearboxes have the same final drive--if not, you will need the rear diff in addition to the manual tranny, and possibly the driveshaft as well.

Otherwise, you'll need front axles, pedal cluster, and shift box in addition to the tranny itself. The end of your crank will need machining for the pilot bearing, then you need the ECU recoded, or maybe a new one that is programmed for the manual tranny.

Search on Audizine as there are a number of threads documenting auto to manual swaps. They will give you a real good idea as to what you will need to do and spend.

I love my B5 A4 with quattro and manual tranny. My B5 Passat with tip (fwd) feels a bit more blunted. If you have the wherewithal and you car is otherwise perfect, I say go for it. If not, you could always find one that came with a manual tranny from the factory.

 

Final drives on auto and manual are not the same so rear end will need to be changed, pilot bearing is built into the flywheel on the v6 so no need to touch the crank.

You just have to decide if you want to go with a 5 or 6 speed tranny


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Double check on that final drive. The front should be 3.89 but I think the rear was 4.11 already. The 4MO Tip has a slight gear reduction effect on the front wheels (from what I was looking at in the Bentley). The final on the Audi S4, A6 2.7T 6sp manuals will be 4.11. Do not get an allroad 6sp as they use different gearing. Not sure what the final on the W8 was. Just watch out for the 6sp manuals as many have a 1-2 shift problem.

 

W8 auto rear end is 3.89, manual is 4.11

All the other auto rear end both v6 and 1.8t are 4.11 manual 1.8t is 3.89


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Go over to tdiclub.com and check out the B5 Passat forum there. There are many examples of auto to manual swaps there with plenty of information and pictures, granted not specific to a gasoline V6 but a lot of the information can be applied across the platform.

 

I did manage to find a couple of manual swap threads on the audizine website and the approximate price for doing a manual swap yourself is about $2,000 in parts. So to all the other members reading this thread, if your transmission does manage to go out you might as well do the manual swap. Repairing the Triptronic gets to be expensive and the 5 speed A4 tranny is much easier and less expensive to preform maintenance on, or so I have been told. Thank you guys for all your feedback! When I get around to making the funds for this project I will be sure to post some pictures of my progress.

 

These were my costs for a 1.8 FWD, junkyards offer discounts sometimes, and on some parts I got lucky, some not:

Transmission $430 (VW dealer)
Axles $60 (junkyard)
Pedal cluster $30 (junkyard)
Clutch slave & master cylinders, lines, $60 (junkyard)
Shift box with arms $30 (junkyard)
Trans brackets $35 (junkyard & eBay)
Clutch kit $600 (ECS)
Trans fluid $85 (VW dealer)

Those are more or less basic parts. I have spent way more than that as I upgraded other parts, like JHM shifter and linkage, new axle boots, manual crank, crank seals, new bearings, EFK, new mounts, new radiator, timing belt kit, custom PCV....... Little things like brake cleaners, degreasers add up too, plus whatever else you need for your 4MO. Around $2K sounds about right just for the swap. It does take time sourcing things. I started gathering parts in August. Due to my family and work, I can only do car work one or two days a week, but should be done over Thanksgiving. And yeah, my auto tranny did go bad after 220K (slipping in reverse, 3rd & 4th). It's a fun swap for sure, I think some members here have done it more than once. Good luck if you end up doing it

 

These were my costs for a 1.8 FWD, junkyards offer discounts sometimes, and on some parts I got lucky, some not:

Transmission $430 (VW dealer)
Axles $60 (junkyard)
Pedal cluster $30 (junkyard)
Clutch slave & master cylinders, lines, $60 (junkyard)
Shift box with arms $30 (junkyard)
Trans brackets $35 (junkyard & eBay)
Clutch kit $600 (ECS)
Trans fluid $85 (VW dealer)

Was just wondering about this myself if/when my tranny goes tits up on my 4motion wagon.

For a 4motion is think that a driveshaft from a 2004 1.8T 4Mo 5-Speed is also required.

 

Wasn't there just a VW sales bulletin or something that went out that had transmissions for dirt-cheap from the dealer? Brand new.

 

WHAA?
I didn't get that memo.
I just puked up 550 clams for a valve body :banghead:

 

That's where I got mine, $399 plus tax. That was in September, so they might still have a few. But as Bdubskii said, they are remanufactured, not exactly brand new.