Swapping M/T for A/T

[talonDSMerr]

hey guys, i just recently registered but i've been reading this forum for quite a while and theres a ton of useful info out there! that being said, id like to ask some of the more experienced tuners if anyone has done a M/T swap into a stock A/T 91 AWD Tsi?

could someone possibly provide a list of parts i'd need to buy to make the swap?
i know i need...
-AWD 5 spd tranny
-Clutch disk
-clutch master cylinder
-pressure plate
-axle shaft
-Driveshaft
-Flywheel
-Shift cables

would it be similar to swapping a 2g auto to manual http://www.dsmtuners.com/forums/showthread.php?t=231626 ?
anything you can think of? thanks a lot!http://www.dsmtuners.com/forums/showthread.php?t=231626

 

[Indyxc]

Not 100% sure, but I also think you need a new transfer case, and rear differential as the gear rations are different.

Hopefully someone can clarify.

 

[talonDSMerr]

alright, i'll add that to my list, thanks.

does anyone know anyone who has a manual 91 Tsi sitting around or are parting?

 

[MountainDew]

You'll also need simple stuff like boot, knob, manual center console?, clutch pedal assembly.

You could get most of this stuff at a junkyard for very cheap. I'd recomend doing that for everything except the tranny itself, clutch, flywheel, etc.

 

[talonDSMerr]

yea, thats probably what i'll end up doing, i havent been able to find anyone who has all of the stuff intact cause i prefer buying it all from one place than separately. thanks for the idea!

im going to be trying to do this myself so after taking out the auto, would it just be a matter of bolting in the respective parts or would there be drilling and more complicated tools involved?

 

[MountainDew]

yea, thats probably what i'll end up doing, i havent been able to find anyone who has all of the stuff intact cause i prefer buying it all from one place than separately. thanks for the idea!

im going to be trying to do this myself so after taking out the auto, would it just be a matter of bolting in the respective parts or would there be drilling and more complicated tools involved?

Option B, unfortunately. You will need to drill holes through the firewall for everything. IMO it would be much easier with the motor and tranny OUT of the car. Well tranny for sure obviously. But with the motor out you could literally crawl in the engine bay and work.

It will be a time consuming process but if it's worth it then best of luck to you. IMO if you can sell the car for a decent price because it's in good shape, then I'd just sell it and buying an MT car. Otherwise if it's a project car or something then I say go for it.

 

[staticbrainwash]

I will swap you my whole a/t set up, for you m/t. Haha.

Whoops, read that wrong.

a/t to m/t swaps have been done a lot. It's not hard at all, just time consuming.

 

[talonDSMerr]

yea, im looking at this as a project car and i couldnt find a better/cheaper 1g DSM that had M/T so i'll be looking forward to doing the swap and spending some time getting to know my car. Thanks for the encouragement guys!!

how much can i expect to pay for it all at a junkyard?

 

[Geezus_Aach]

your also going to need the brake and clutch pedals.

i would say you may want to take a look at this link:
http://www.ecanfix.com/~mdhamilton/autotomanual.html

(taken from www.vfaq.com)

 

[talonDSMerr]

wow, thats a real useful site, thanks a lot Geezus. i just have to gather the parts now.

does anyone know of a junkyard in the midwest, preferably around chicago that sells dsm parts?

 

[staticbrainwash]

Most if not ALL yards probably have dsm's. It's just finding them.

Honestly, there are for sure things i'd buy new.

Clutch slave and master, All the lines, and probably the clutch and flywheel. I've heard that most swappers like to buy new clutch pedals too. Along with that get a JNZ short throw so you can just bolt it in, and the rest get used.

 

[Geezus_Aach]

...and while youre at it, start reading this....read it all!

http://www.vfaq.com/index-main.html

 

[MountainDew]

This is a possibility.. I live in Kansas and there is a pick and pull junkyard out here. There are always manual 4g63 cars out there. I could POSSIBLY pull parts for you and charge you a small labor fee then ship them to ya.

If you can't find some stuff just let me know and I'd be more then happy to keep an eye out for you.

 

[talonDSMerr]

thanks a ton for all the useful input guys! i'll be sure to start reading vfaq.

Static, im gonna try to get those parts new but i have to stay within a budget. do you think getting all those parts new now is worth waiting for? or should i get them used for now for cheaper and install the new parts gradually after getting my M/T running first?

MD, thanks for giving me another option, i really appreciate it. if i had to have all the parts pulled from a used manual 4g63, how much do you think it would cost?

again, thanks a lot, you guys have been real helpful.

 

[staticbrainwash]

Personally, i'd go new now. Less worry, and less cost in the long run.

JNZ will have EVERYTHING you need now that they're hooked into trademotion's oe mitsu stuff.

 

[MountainDew]

thanks a ton for all the useful input guys! i'll be sure to start reading vfaq.

Static, im gonna try to get those parts new but i have to stay within a budget. do you think getting all those parts new now is worth waiting for? or should i get them used for now for cheaper and install the new parts gradually after getting my M/T running first?

MD, thanks for giving me another option, i really appreciate it. if i had to have all the parts pulled from a used manual 4g63, how much do you think it would cost?

again, thanks a lot, you guys have been real helpful.

It really just depends. If you can, try and do it at a Pick and Pull type junkyard. I've noticed they are always cheaper. I could probably pull a complete manual swap for like $150 at my local junkyard. Probably about $60-$80 for the parts you're wanting to use though.

Only bad thing is you don't know why the car is in there, especially if it isn't wrecked.. Who knows if it could be engine or tranny. Sometimes you get lucky though, but I wouldn't risk it and just get a rebuilt tranny and a new clutch/pressure plate.

 

[Littlebeeper]

the pic n pull here gives a warranty and sells an extended/lifetime warranty on certain parts. only thing is you would have to find another car with the same part if it doesn't work. or wait some time for them to get another car in if the part isn't found. also you have to do the work of getting the damn thing off. a tranny/rear end/transfer case would be some work in this case.

 

[talonDSMerr]

hmm, i dont know if i'd be willing to take the risk of junkyard parts... plus, i wouldnt want too much mileage on the tranny and clutch/flywheel so i'm leaning towards getting those off ebay.

the cheaper things, do you think you guys could pull them from the junkyard for me? stuff like the shifter assembly, boot, cables, cable hold downs, firewall gaskets, pedal assembly, flywheel to crankshaft bolts?

i dont think i'd have time to perform the swap til next summer so i'll just be trying to gather all the parts this year.

thanks a lot for the help guys!

 

[staticbrainwash]

hmm, i dont know if i'd be willing to take the risk of junkyard parts... plus, i wouldnt want too much mileage on the tranny and clutch/flywheel so i'm leaning towards getting those off ebay.

the cheaper things, do you think you guys could pull them from the junkyard for me? stuff like the shifter assembly, boot, cables, cable hold downs, firewall gaskets, pedal assembly, flywheel to crankshaft bolts?

i dont think i'd have time to perform the swap til next summer so i'll just be trying to gather all the parts this year.

thanks a lot for the help guys!

Thats exactly what i'm doing too. Slowly building up the parts to do the swap. That way i know i've got the best of the best and i'm not screwed because i've got a timeframe to do it this year. JNZ might have that stuff too honestly, but i'm sure another tuner can help you out from a parts car too.

 

[talonDSMerr]

are you doing the swap next summer too? and is JNZ an online shop or junkyard?

 

[staticbrainwash]

jnztuning.com is the site. They are awesome guys.

And yes, my build will happen when i'm back from school next summer. Full swap with a tre trans, 2600 (esque clutch), stock flywheel, and all new pedals and master/slave. (and short throw)

It's going to be SWEEEET!

 

[talonDSMerr]

haha, dude, i can't wait to get started on mine too! im looking at an F1 stage 3 clutch and flywheel assembly on ebay, its gonna feel so sexay!

didnt you say you were getting a new flywheel? how much are you expecting to spend on the swap?

 

[staticbrainwash]

A lot more than i need to, haha.

Im buying a used trans, xfer, and rear. Then sending the trans out to get built. Then probably 300 on clutch, about 200 on master/slave and lines. Then i'm buying the jnz short throw, which is 150ish. So it's going to be up there. But still probably not as much as buying a built a/t.

Honestly though, for DD and drag, i was going to keep the a/t. But i want to get into autox hard, so i'm going manual.

 

[MountainDew]

hmm, i dont know if i'd be willing to take the risk of junkyard parts... plus, i wouldnt want too much mileage on the tranny and clutch/flywheel so i'm leaning towards getting those off ebay.

the cheaper things, do you think you guys could pull them from the junkyard for me? stuff like the shifter assembly, boot, cables, cable hold downs, firewall gaskets, pedal assembly, flywheel to crankshaft bolts?

i dont think i'd have time to perform the swap til next summer so i'll just be trying to gather all the parts this year.

thanks a lot for the help guys!

Yes I think all that from a junkyard would be fine.

Infact.. IF you can afford to do this.. pull a tranny from a junkyard, pay $100 for it (thats what they go for here) and send it to TRE. I have a TRE in my car and I love it! I know if you send them the core they give you a pretty big discount. Again this is only if you could afford it. Your car is AWD right? IMO it'd be much worth it. Paired with an ACT Stage 3 clutch and lightened flywheel, thing would be a beast.

I just figured if you're going to swap next summer, you'd have plenty of time to save up for a TRE. Hell you could order it in like April or May while you're still getting the swap ready. You could also get all your linkage and what not figured out and assembled before hand.

 

[talonDSMerr]

i just think manual's a whole lot funner to drive than auto.

MD, i think right now, my plan is to get the cheap stuff from a junkyard while getting new clutch and flywheel stuff off ebay. are you recommending me to send a tranny to TRE to rebuild or do they exchange autos for manuals? i dont know if i would be able to afford sending it in tho, since a tranny with about 43K miles goes for about 500 on ebay. and yea, my car is AWD. but do you think you'd be able to pick and pull the cheap stuff for me and ship it over? i'd really appreciate it, but if you cant its fine too. thanks a bunch!