CVT to 6 speed manual swap

[djsp00kyk]

Just starting a thread to keep people in the loop of my progress and issues with the swap. I will try to take as many pics as I can and may even do a DIY when I am finished.

My parts list:
FWD GVD transmission
Complete pedal assembly
Clutch switch
master cylinder
slave cylinder
dual mass flywheel
Luk clutch kit
flywheel bolts
pressure plate bolts
JHM braided clutch line
Shifter assembly with selector/connecting rods
Left and right CV axles
Vag-com cable (for possible recoding)

I will update the list as I do the swap with whatever parts are missing. So far I have spent a little over 2k and I will add up the complete total once finished. Wish me luck!!

Issues and discoveries:

The manual tranny requires two longer bolts that the CVT to bolt to the block, plus a long nut bolt combo for the bottom passenger side and a "hammerhead" bolt for the driver side.

Get a Manual STARTER as it differs from autos.

The rear frame support is different on CVT cars than manual/quattros so either get a new support or make a new trans mount bracket as I did.

Getting the wiper arm off is a bitch... so buy a puller or get creative!!

Had to shim out the tranny just a hair more than the intermediate plate provided, I custom cut a spacer plate. (Didn't know it at the time but an 01E transmission ring is required which is why had the clearance issues)

Clutch switch wire goes to PIN 41 on the larger 94 pin ecu plug. The other tapped into the second wire from the top of the brake switch harness (two wires merged into this one pin slot)

[dbens]

Awesome. Wish i had the balls to attempt something like this.... might i suggest you also do the FWD to AWD swap while youre at it? Theres a DIY on how to do it by viziers i believe.....

[viziers]

If your going to convert it from cvt to 6sdd why not go the extra bit and go 6spd awd???

[Avantageous]

I concur, 6spd and AWD!!!!!!!!!!!!!!!!!!!!

[PDX04a4]

ya, there is pretty much no reason to go from a CVT to 6spd without also doing a FWD to AWD conversion as well.

[Jake@JHM]

Just starting a thread to keep people in the loop of my progress and issues with the swap. I will try to take as many pics as I can and may even do a DIY when I am finished.

My parts list:
FWD GVD transmission
Complete pedal assembly
Clutch switch
master cylinder
slave cylinder
JHM SINGLE Mass Lightweight Flywheel and Clutch Combo
Luk clutch kit
flywheel bolts
pressure plate bolts
JHM braided clutch line
Shifter assembly with selector/connecting rods
Left and right CV axles
Vag-com cable (for possible recoding)

I will update the list as I do the swap with whatever parts are missing. So far I have spent a little over 2k and I will add up the complete total once finished. Wish me luck!!

Fixed

[ultraleggera a4]

Just starting a thread to keep people in the loop of my progress and issues with the swap. I will try to take as many pics as I can and may even do a DIY when I am finished.

My parts list:
FWD GVD transmission
Complete pedal assembly
Clutch switch
master cylinder
slave cylinder
dual mass flywheel
Luk clutch kit
flywheel bolts
pressure plate bolts
JHM braided clutch line
Shifter assembly with selector/connecting rods
Left and right CV axles
Vag-com cable (for possible recoding)

I will update the list as I do the swap with whatever parts are missing. So far I have spent a little over 2k and I will add up the complete total once finished. Wish me luck!!

I'm in the process myself of getting parts together to do a swap, keep my updated on your progress and foreseen expenses .

[pkny]

Just curious, but what is the price difference if you were to trade in your car for a comparable one with a manual quattro.

[viziers]

Just curious, but what is the price difference if you were to trade in your car for a comparable one with a manual quattro.

For me it was cheaper to do the conversion.


vizi

[djsp00kyk]

ya, there is pretty much no reason to go from a CVT to 6spd without also doing a FWD to AWD conversion as well.

I had a car lined up to to just that and even bid on drakes old ride on copart but all that fell through. I need to get my car going in the next week or so, which is why I am just going for fwd at the moment. I will AWD once my motor goes and I decide what engine to use to replace it. This is just a temporary step towards AWD 2.7.... or what ever I decide, motor wise.

[djsp00kyk]

Fixed

I thought about just going all out on a clutch and single mass flywheel set, but I will do that once I go AWD. I may end up ordering the shifter/linkage kit from you guys though once its all said and done.

@pkny, I have 252k on my car so I am stuck with it, so doing a conversion will end up being cheaper as Vizi stated earlier.

[dbens]

wow! how do you rack up that kind of mileage? Im pretty sure you have the highest mileage b7 on the forum..... congrats!

[djsp00kyk]

wow! how do you rack up that kind of mileage? Im pretty sure you have the highest mileage b7 on the forum..... congrats!

Haha, I drive 130 miles a day for work. The A4 has been my reliable DD for years now. I've definitely got my money's worth out of her!

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[djsp00kyk]

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[djsp00kyk]

Does anyone have a picture of what goes in here it appears to be a wedge of some sort but I am missing it. Can this be fabricated? I'm sure the dealer doesn't have it and I can't wait till next week.


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[djsp00kyk]

Found a metal slave cylinder locally to go with my usp clutch line.


Here are some pics of the shift levers, it would have helped me if someone would have posted these pics somewhere, to know what I needed to buy.




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[yeoj112689]

Very fun thread. I plan on attempting this if my tiptronic ever shits out on me. I came from a 5 speed for the past 2 years to an auto.. sucks a bit.

[djsp00kyk]

First hurdle. Can't seem to login based off the ross-tech site to recode the Abs module. I did get the ecu coded to manual and the cluster so I am proceeding on with abs and esp errors. If anyone has any ideas or knows what the login chart is for the b7 please chime in, I would appreciate it greatly.

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[djsp00kyk]

Audi up in the air, would be nice to have a lift right now..


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[djsp00kyk]

Just some reference pics.






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[djsp00kyk]

I can confirm now that the manual crankshaft and cvt are indeed the same. I figured the cvt would use a pilot bearing but to my surprise it didn't, made installing my new one a breeze. Also the transmission bolts are different lengths for the 6 speed, I could only reuse 2 of the of the 5 that bolt to the block, three are too short.

Also the starter is different on the manual transmission, slipped my mind until I tried to bolt the old one on..

OP UPDATED.

[djsp00kyk]

So I try to start my car after the swap and the starter clicks, ok... Check and charge battery, try again, click slow dragging roll for 1/2 sec then nothing. I pull the new starter check it out and it's fine. Try again and now grinding and engine attempts to run but is drug down almost immediately! What the hell could be binding up!? Is there a spacer or thicker tranny shim plate on a manual car? Not a good day! Looks like I'm pulling the transmission to investigate...!

[AudiA4_20T]

Can you spin the motor freely by the crank bolt?

[AudiA4_20T]

BTW, why wouldn't you go AWD when you do 6 speed? Maybe because it costs a ton more. Also, could have used a B5 A4/Passat FWD 5 speed if you were strapped for cash.

[djsp00kyk]

Can you spin the motor freely by the crank bolt?

Not sure yet. I have to jack her up and start troubleshooting here in a minute.

[djsp00kyk]

BTW, why wouldn't you go AWD when you do 6 speed? Maybe because it costs a ton more. Also, could have used a B5 A4/Passat FWD 5 speed if you were strapped for cash.

Cost and time were definitely things to consider when sourcing parts. I'm sure the 5speed would bolt up but I'm not sure they are that much cheaper, and they have a different shift lever setup than the 6speed.

[AudiA4_20T]

Cost and time were definitely things to consider when sourcing parts. I'm sure the 5speed would bolt up but I'm not sure they are that much cheaper, and they have a different shift lever setup than the 6speed.

Well they're like $100 at the junkyard. Not sure how much you got yours for. Yes you would need different linkage. I was just saying in a pinch. You did it the right way

[djsp00kyk]

Damn that is cheap! I guess on a budget that would be the way to go.

[djsp00kyk]

Well it looks like the clutch it contacting the bell housing... Just barely and just enough! Still don't understand why but at least I've found the binding problem!

[djsp00kyk]

It looks like jumping out the neutral safety switch (blue clutch switch) is easier than I thought here is the relay to jump out. (black 395 on the left)

Here is what it looks like jumped out

[djsp00kyk]

To wire in the clutch switch just run a wire from pin 41 on the larger 96 pin ecu connector to the clutch switch. Then tap the other wire on the clutch switch to dual wire pin on the brake switch. I had to make a 'pull a part' run to find a small enough pin for the ecu. Luckily I found a perfect size (tiny) pin in a jetta, it was a yellow connector I'm assuming goes to the restaint system. Cruise control works and the rpms don't jump/hang as bad now when shifting, although they do seem to hang a when shifting quickly from 1st... I broke my white clutch switch, but substituted it with the blue one for now, not sure if that's the cause. I will post pics of everything when I edit them.

[djsp00kyk]

Does anybody know what can cause "rev hang" issues. I have been trying to deal with and eliminate this issue ever since doing the swap. I have a working and functional F36 clutch switch. I have cleaned the MAF and even tried running with it unhooked. My next guess would be a new firmware flash but would an old flash cause the major hanging RPM's that cause me to wait, at least a second, in neutral between shifts just to engage the next gear?! Any input and ideas would be appreciated as I have yet to enjoy the pleasure of a real shift in the audi yet!

[Shimon]

Does anybody know what can cause "rev hang" issues. I have been trying to deal with and eliminate this issue ever since doing the swap. I have a working and functional F36 clutch switch. I have cleaned the MAF and even tried running with it unhooked. My next guess would be a new firmware flash but would an old flash cause the major hanging RPM's that cause me to wait, at least a second, in neutral between shifts just to engage the next gear?! Any input and ideas would be appreciated as I have yet to enjoy the pleasure of a real shift in the audi yet!

hey buddy did you ever fix the hang up issues? also the only wiring you will be doing when going from cvt to manual is the clutch switch reverse light and neutral safety switch?

[allstock]

[QUOTE=viziers;9170003]If your going to convert it from cvt to 6sdd why not go the extra bit and go 6spd awd???[/QUOT

@djsp00kyk: More power I'm all for it. I think fwd GVT tranny is cool. Not as cool as awd conversation, but still cool.

[djsp00kyk]

hey buddy did you ever fix the hang up issues? also the only wiring you will be doing when going from cvt to manual is the clutch switch reverse light and neutral safety switch?

That's right those are the only things that have to be wired but the ecu, abs module and gauge cluster have to be reprogrammed. I never did get rid of the rev hang issue but I haven't been driving it for the last month or so due to the cam chain tensioner going out.

[djsp00kyk]

[QUOTE=allstock;9956068]

If your going to convert it from cvt to 6sdd why not go the extra bit and go 6spd awd???[/QUOT

@djsp00kyk: More power I'm all for it. I think fwd GVT tranny is cool. Not as cool as awd conversation, but still cool.

I agree but I was in a rush and the awd was going to take too long. If time wasn't an issue then I would have done the whole nine yards.

[allstock]

That's right those are the only things that have to be wired but the ecu, abs module and Guage cluster have to be reprogrammed. I never did get rid of the rev hang issue but I haven't been driving it for the last month or so due to the cam chain tensioner going out.

So you still haven't had any assistance with reprogramming? I think there's another guy that swapped a b6 that has a write up. I wonder what would cause the rev issue. Maybe once reprogramming is done that'll fix??

[djsp00kyk]

So you still haven't had any assistance with reprogramming? I think there's another guy that swapped a b6 that has a write up. I wonder what would cause the rev issue. Maybe once reprogramming is done that'll fix??

I got reprogrammed but I think it's a firmware issue. I'm sure newer firmware would reduce the rev hang quite a bit, but I didn't want to take it to the dealer just for a firmware flash.

[allstock]

Ah okay that makes sense. Wonder how much it would be for them to reflashed if they did.

And you got 250k out of your CVT without issue?!

[djsp00kyk]

Ah okay that makes sense. Wonder how much it would be for them to reflashed if they did.

And you got 250k out of your CVT without issue?!

Yea 252k but did have the TCM changed at around the 120k mark. Not sure how much they would charge to flash. I had a dude reprogram mine with Vag com but only the dealer can flash updated firmware as far as I know.