Swap 92 AWD Tranny into 90 car? (Merged)

[project_tsi]

Hey guys, ive got a 90 tsi awd and my trans is shot, so im gonna swap in from a 92 tsi awd the six bolt engine, ecu, trans, t-case, driveshaft, and 4 bolt rear but ive got a problem w/ the tranny. what differeces, if any does the 92 tranny have vs. the 90 tranny. ive heard of people saying that i may have to swap out the shifter cables, and use w/ the 92 tranny or it wont shift correctly or not at all. ive also heard that the small connecting rod on the tranny that connects the shifter cables to it has to be swapped because its a different lenght, but i dont know for sure, any ones help would be greatly appreciated.

 

[AWDgsx905speed]

You need to replace the shifter and assembly, shift cables, and also the bracket on the transmission that holds the cables. If you need any of these parts I have all of them. I also put a thread in here that should answer any other questions you may have.
http://www.dsmtuners.com/forums/showthread.php?t=93739&page=2&pp=25

 

[jazzyjay]

I am I the process of swap out a awd tranny in 90 talon with 92 tranny. I need a list of parts or a how to for this swap. Thanks in advance.

 

[Quasimondo]

You'll need the transfer case from a 92 awd (90's and 92's have different spline counts on the output shaft), and possibly the shifter assembly, I'm not too sure about this.

http://members.shaw.ca/costall/1000Q/answers-conversions.htm#manualtransmissioncompatibility

 

[Phatblackhatch]

Hey guys and gals,

I have seen all over that if you put a 91-94 tranny into a 90...U need to change cables. My question is, if I change cables, do I need to change the shifter and shifter plate as well. As we all know the 1990 shifter plate is different than the 91-94.

My 90 awd bell housing is cracked , and I got a 92 tranny from a friend, but i need to know if saturday morning needs to be a junk yard run.

Thanks in advance for the help.

 

[DSM90AWD]

Yes, you need the shifter plate/shifter assembly to use the 91-94 cables.

BTW.. bellhousings can be welded

 

[Lunch_Box]

The input shaft going into the transfer case will be different between the 2 years. You have a 22 spline transfer case and are putting on a tranny with a 23 spline input shaft.

 

[kelvinb]

is there any difference in cables between an awd and fwd? im kind of doing the same thing and have the chance to get fwd linkage but im awd.

 

[project_tsi]

is there any difference in cables between an awd and fwd? im kind of doing the same thing and have the chance to get fwd linkage but im awd.

No, they are the same. I did the entire swap into a 90 awd using 92 parts. I needed the cables, the shifter column floor housing, the tranny, rear end, and driveshaft, b/c the splines are a different count, and you'll majorly screw it up if you don't use the right tranny transfer case.

 

[DSM90AWD]

you'll majorly screw it up if you don't use the right tranny transfer case.

Thankfully the spline count is different so unless you have access to a 30-ton press, you'd never be able to mount the two together

BTW.. the output shaft is interchangable between the 22/23 spline trannies. I've never done this myself, but was told about as much work as changing out the VC for FWD dyno testing. Though for $100 you can pick up a 23-spline X-Fer case and the added strength

 

[project_tsi]

Are the T-cases swappable? Like if he got a 92 tranny, could he just install his 90 T-case into the tranny so he didn't have to swap output shafts or other drivetrain parts?

 

[Phatblackhatch]

Thanks for the info. I know bell housings can be welded, that was the initial plan but my friend had the 92 tranny and transfer case (both 23 spline) kicking around. After droping the box, I am glad he did, it was cracked in 3 different places.
I was curious about the FWD cables and shifter too, the junkyard here has a fwd tsi that I could get that stuff from, so I was glad to hear, that they where the same. So I am going to make a trip to the yard to collect the shifter and cables from the fwd..

However :

No, they are the same. I did the entire swap into a 90 awd using 92 parts. I needed the cables, the shifter column floor housing, the tranny, rear end, and driveshaft, b/c the splines are a different count, and you'll majorly screw it up if you don't use the right tranny transfer case.

I thought the drive shafts were same through out the 90-94. I just needed the tranny and matching transfer case (same spline count). If this is the case, I may need to weld the 90 box, and hope it doesnt crack anytime soon. then, and gather the rest of the 92 stuff...4 bolt rear etc...

Thanks again

 

[DSM90AWD]

I thought the drive shafts were same through out the 90-94.

They are the same. You do not need to swap driveshafts

 

[Phatblackhatch]

They are the same. You do not need to swap driveshafts

PERFECT.

I called the yard about the FWD tsi shifter/cables, they said its gone but they have a 4 bolt diff kicking around, but its from an auto. Would it be a good idea to use a 4 bolt rear from an Auto in my 5 speed. They said they could do like $40 for it. If its not such a good idea, I may put it off for now, just so I can get my car back up and runnin; But I can bet my left finger, that when I am ready to do the 4 bolt swap, The cheapest I can a setup for will be $200....but thats life I guess.

 

[DSM90AWD]

Would it be a good idea to use a 4 bolt rear from an Auto in my 5 speed. They said they could do like $40 for it.

The A/T has a different final drive ratio than the M/T so if you use dit.. would burn out your Viscous Coupler pretty quickly.

For $40 why not pick it up and put on the Tuners classifides. You'd make a nice little profit for this undervalued part

 

[Phatblackhatch]

I came across a shifter and cables, from a 94 n/t , are these the same as ours? Since the FWD turbo will work, i am really really hoping that these will work, because i want to scoop them up like ice cream... ...but I figure i would consult with you guys 1st.

 

[Phatblackhatch]

I got some pictures of the base and the cables, they look pretty much the same, as the turbo versions [on Vfaq for example, was my reference point, hehe hehe]. I know there are some things that are generic across all models, and I am hoping that the shifter assembly and cables are 1 of those things (you know like the, door panels, power window control, driveshaft )

 

[Phatblackhatch]

Well, I bit the bullet, I bought the FWD 94 shifter base and cables, the guy is in Atlanta, so It should be here by saturday I am hoping, which would make life easier for me, I could throw it all back together, anyway I will let you guys know how it turned out.

kelvinb keep your fingers crossed, if it works out fine, I'll PM and let you know. just in case the thread gets lost...

 

[kelvinb]

you should be ok, yesterday i successfully installed my 1990 nt fwd 4g63 shifter base, cables and tranny bracket and I have every gear I also purchased these for 25 bucks from the junk yard. Just an FYI, the bracket that goes on the tranny is taller then the one my car came with (91). So nt fwd cables are swappable as long as its from a 90.

 

[Phatblackhatch]

you should be ok, yesterday i successfully installed my 1990 nt fwd 4g63 shifter base, cables and tranny bracket and I have every gear I also purchased these for 25 bucks from the junk yard. Just an FYI, the bracket that goes on the tranny is taller then the one my car came with (91). So nt fwd cables are swappable as long as its from a 90.

Good to hear . I just now need to wait on these to come in, and then I can finally get the car back together. I need to do this quick, because, stuff hasnt looked so cheap on ebay, I am about to get myself in debt, with the " well since its down, I could do this..."....NOT GOOD....

ANYWAY I'll keep you guys posted.

 

[kelvinb]

Just an FYI, 4 bolts holding the base down, 1 is under a cable so you have to take the cables off no matter what. 12mm nut holding the cables down between the ecu and the fire wall, 2 12mm bolts to a bracket on the firewall on the inside. Watch out for the wiring of the ecu when you pull out the cables. Other then that you should be good.

 

[Phatblackhatch]

Good looking out....

Thankx

 

[Deez]

Why are you guys changing out the cables? All I changed was the shifter plate (the one that holds the cables to the tranny) and all is well. I have all gears without any problems. This is a 91 tranny / t-case in a 90.

 

[Phatblackhatch]

Not to beat a dead horse...As I was changing brackets on the tranny to the 90 bracket I thought about this, and before I continue, can someone explain to me why I need to change the bracket on the tranny that holds the cables to the 90, if everything related to gear changing is from a 91-94 ( tranny/t-case, shifter + cables), why do i need the 90 bracket . Makes no sense to me.
Some people have said they just changed tranny and case, and that was it, some people have had the gear [or lack there of] problem...so I am confused , I am going to try it tonight, and test the car with both brakcets when done, and see the results..it just doesnt make sense to me. I just want some clarity on the issue.

However besides this, I have been able to get a lot of convience mods done, during this down time......fuel filter catch can ( FRAM G12 - $3 @ walmart . ) Silcone packed carrier bearings, JB welded my broken flex plate, several other small details..go figure

 

[Phatblackhatch]

DEEZ,

When I looked at them, the cables where different between the 90 and the 91-94. just rough measurement laying them on the floor, it seemed to me that he 91-94, had one longe and 1 shorter cable..as opposed to the 90, which had a smaller difference in the distance between cables and where they attach to the shifter base..

Just my $0.02