What would it take to convert my 1995 tsi from auto to manual?

[versatilx1]

i have a 1995 tsi and i wanted to know what i would have to do about converting to manual and what kind of tools could be needed?

 

[1GTSiAWD]

Your best bet will probably be to get a hold of someone who has done it.

http://www.dsmtuners.com/forums/showthread.php?p=1637459#post1637459

It will be very expensive though.

 

[versatilx1]

Yeah but thats a fwd car and so forth i need someone with some experience with a dsm awd if anyone can help links are welcomed

 

[FullyBuiltDSM]

WHAT YOU NEED
1. manual pedal assembly
2. manual shifter assembly and linkage
3. mastercylender and clutch line
4.manual trans.


Its not as hard as you think it just takes some time. First you need to take out your dashboard and your steering columb so you can get full access to your firewall and pedal assembly. Next your going to take out your automatic pedal assembly. Its basically the whole pedal shaft connected to another support bar that runs up over your gaspedal.(note. before you take it out be sure to unplug sensors ect.) once thats out pop your hood and on ur firewall next to where u fill your power steering you will see a round circle pattern that hasnt been cut out. Take a hole saw about the size of the pattern then cut it. (smooth edges) This is where your mastercylender will go through. Now Take your manual pedal assembly and bolt it up exactly where the auto. was, it fits perfectly with all the same hardware. Ull notice theres an extra sensor outlet on the back of the clutch. Dont worry youll find that plug tapped up on the harness, just simply untape it and plug it in. Next you will install your master cylender as if uve always had a manual(slide it through firewall and hook it to clutch link) Now screw your clutch line to the mastercylender and run it to its correct position, which is easy because its pre bent. Now you should have your pedal assembly in its time for your linkage. take out your auto shifter and pull disconnected linkage through the firewall and out(pull hard). Your manual shifter will bolt directly to the four holes ur auto did. After thats in ull need to pop the hood again. Look on the firewall just behind where ur tranny is and there will be a spot in the heat lining that is open but for no apparent reason. This is where the linkage will go through. Cut this out however u feel is easiest, but be careful you dont cut outside the lines. (make sure no wires are against the firewall on the inside in that area) When your done cutting slide your 5 speed linkage through and up to your shifter. Hook up the linkage and thats pretty much it. Theres a rubber piece around the linkage slide that down to where the cut in the firewall is to seal around the linkage...This was extremly hard to explain if u have ANY QUESTIONS OR DOUBT message me and ill walk you through it.

 

[TotalEclipse112]

Its not worth the hassle. DSM's are so cheap these days, in fact with DSM's its usually buy one get one free. So unless you have some sever attachement to your car(which I will never understand) just go out and pick up a manual one.

 

[tim4g63fast]

I talked to m & s recyclers about doing it once on my old 2g. I think they quoted me at 1600$ for what he said was absolutely everything to do the sway. I heard its a lot of work and would imagine so. I don't know how much the automatic differs from the manual but when i was looking into doing this I was told that the car had all the bolt holes and everything to hook up stuff such as mater and slave cylinders, clutch pedal and whatever Else needs to be done. I never ended up doing it so I'm not completely for sure just something you may look into. If not I would imagine there would be a lot of hole drilling. Like everyone Else said its really not worth it.

Honestly with the money your going to spend doing it you can build the hell out of your automatic transmission. It will out run manuals all day long. There was a thread not to long ago about this posted. And that would be cool.

 

[versatilx1]

yeah sounds about right i had done this before but with a honda civic hb si and it wasnt hard sounds about the right way to go about doing this process

 

[Sbeing1]

hmm so thats all i need to do....? i read that id also need a new rear diff and maybe a ecu? are you sure thats all i need to do the swap? thanks

 

[hellotbone]

WHAT YOU NEED
1. manual pedal assembly
2. manual shifter assembly and linkage
3. mastercylender and clutch line
4.manual trans.


Its not as hard as you think it just takes some time. First you need to take out your dashboard and your steering columb so you can get full access to your firewall and pedal assembly. Next your going to take out your automatic pedal assembly. Its basically the whole pedal shaft connected to another support bar that runs up over your gaspedal.(note. before you take it out be sure to unplug sensors ect.) once thats out pop your hood and on ## firewall next to where u fill your power steering you will see a round circle pattern that hasnt been cut out. Take a hole saw about the size of the pattern then cut it. (smooth edges) This is where your mastercylender will go through. Now Take your manual pedal assembly and bolt it up exactly where the auto. was, it fits perfectly with all the same hardware. Ull notice theres an extra sensor outlet on the back of the clutch. Dont worry youll find that plug tapped up on the harness, just simply untape it and plug it in. Next you will install your master cylender as if uve always had a manual(slide it through firewall and hook it to clutch link) Now screw your clutch line to the mastercylender and run it to its correct position, which is easy because its pre bent. Now you should have your pedal assembly in its time for your linkage. take out your auto shifter and pull disconnected linkage through the firewall and out(pull hard). Your manual shifter will bolt directly to the four holes ## auto did. After thats in ull need to pop the hood again. Look on the firewall just behind where ## tranny is and there will be a spot in the heat lining that is open but for no apparent reason. This is where the linkage will go through. Cut this out however u feel is easiest, but be careful you dont cut outside the lines. (make sure no wires are against the firewall on the inside in that area) When your done cutting slide your 5 speed linkage through and up to your shifter. Hook up the linkage and thats pretty much it. Theres a rubber piece around the linkage slide that down to where the cut in the firewall is to seal around the linkage...This was extremly hard to explain if u have ANY QUESTIONS OR DOUBT message me and ill walk you through it.

Sounds like your talking 1G not a 2G. The procedure is a bit different on a 2G not much though, the dash DOES NOT HAVE TO COME OUT.

 

[hellotbone]

Its not worth the hassle. DSM's are so cheap these days, in fact with DSM's its usually buy one get one free. So unless you have some sever attachement to your car(which I will never understand) just go out and pick up a manual one.

This is total crap do not listen to this guy, you can do the swap for under 2000 canadian easily I sure did.

 

[hellotbone]

The real deal and I did the swap so you can ask away. This is for a AWD swap.

You need; and trust me its better to get a rolling chassis parts car because everything is there you need.

1)Manual trans and trans mount which mounts the trans to the car's frame they differ from auto to manual.
2)You need the MT transfercase
3)The rear Diff
4)All 4 CV shafts and the intermediate shaft
5)Shifter Cables
6)Shifter
7)Clutch peddle assemble and brake peddle assemble
8)Clutch Master
9)Clutch slave
10)Clutch SS braided hose
11)Clutch
12)Flywheel + bolts
13)The shifter boot and all that crap you can make the AT center console work so no need to replace it.

Im probably forgetting something but thats 99% of it. Its not all that much work really and its all easy and straight forward.

 

[TotalEclipse112]

4)All 4 CV shafts and the intermediate shaft

Why would he need that anyways? Did you neglect to notice that his car is a FWD non turbo. If he wanted to do this swap he would only need 2 cv shafts. Now that is misinformation if I ever saw any.

 

[steve]

Now that is misinformation if I ever saw any.

That's called a mistake (not saying his list was for a AWD conversion) just like you missing calling out the item above #4 and the one above that.

Steve

 

[crankbender]

Yeah but thats a fwd car and so forth i need someone with some experience with a dsm awd if anyone can help links are welcomed

Read the entire thread before assuming things are misinformation. This post would lead one to believe that he is doing this on an AWD car.

 

[hellotbone]

Why would he need that anyways? Did you neglect to notice that his car is a FWD non turbo. If he wanted to do this swap he would only need 2 cv shafts. Now that is misinformation if I ever saw any.

You might want to read what the original poster wrote. He has a TSi he wants to convert to manual. Look right under his name TSi AWD thats why he needs 4 CV shafts.

 

[TimG]

Why would he need that anyways? Did you neglect to notice that his car is a FWD non turbo. If he wanted to do this swap he would only need 2 cv shafts. Now that is misinformation if I ever saw any.

Is it even possible to do a straight forward AWD conversion on a 2G FWD n/t? I don't think so.

Also, he's speaking about an auto TSi AWD in which case I believe you need 4 new shafts.

 

[TotalEclipse112]

Look I made a mistake on this thread, and am admitting it to all. I read the orignal post quicky and didn't get all the details, before postiong. I spoke with hellotbone and cleared the thing up with him. So consider this my formal appology. Once again I am sorry if I stepped on anyones toes here. So please accept my appology.

 

[beast_bl]

Here it is nice and simple like.

Step #1 Wash and Detail current DSM

Step #2 List current DSM in local classifieds.

Step #3 Sell current DSM.

Step#4 Buy proper DSM and proceed with tuning.

There, way easier than any kind of swap or conversion.

 

[TotalEclipse112]

Great here we go again.

BEAST_BL just friendly warning, you might want to read eveything I posted on this thread. It started out much like what you are saying right now.

 

[hellotbone]

Here it is nice and simple like.

Step #1 Wash and Detail current DSM

Step #2 List current DSM in local classifieds.

Step #3 Sell current DSM.

Step#4 Buy proper DSM and proceed with tuning.

There, way easier than any kind of swap or conversion.

Stupid Answer. And again wrong.

 

[TurboFever]

I would like to know where all the people who say DSM's nowadays are cheap shop, because I have been looking for a 2g AWD around my area and they are all hanging around the 10k mark.

 

[98evoIIIpwr]

Have you checked out www.atdsm.com? There are some things you can do to an auto trans that would probably make you change your mind. The money that you spend on the swap can be put towards a high stall converter, shift kit, end clutch, etc. etc. Autos are running pretty good times these days thanks to the help of some shops like IPT . Just a thought, not saying the swap wouldnt be worth it but definetly worth a look into. I myself just bought an awd auto 1st gen. I have been looking into the auto trans stuff and it doesnt seem as bad as its made out to be. Anyways, take a look if you havent already, its some good reading.

 

[beast_bl]

Have you checked out www.atdsm.com? There are some things you can do to an auto trans that would probably make you change your mind. The money that you spend on the swap can be put towards a high stall converter, shift kit, end clutch, etc. etc. Autos are running pretty good times these days thanks to the help of some shops like IPT . Just a thought, not saying the swap wouldnt be worth it but definetly worth a look into. I myself just bought an awd auto 1st gen. I have been looking into the auto trans stuff and it doesnt seem as bad as its made out to be. Anyways, take a look if you havent already, its some good reading.

I agree!!

It all depends on what you want to do with your car. Most of the fastest 1/4 mile cars are indeed automatic. They do have shift kits and such but they are without a clutch. I prefer manual personally because it's just more fun to drive, in my opinion. So, really, it all comes down to what you want to do in your car, and it shouldn't matter what anyone says in this forum. I'm not the typical 'ricer' hating on auto's because they weren't in the fast and furious movies, it's just that from what I've seen, doing the conversion is just not worth while. You get a donor car with old parts that break, or you buy new parts, but they are so many of them, some aren't available and the ones that are cost a fortune!!

 

[TotalEclipse112]

I would like to know where all the people who say DSM's nowadays are cheap shop, because I have been looking for a 2g AWD around my area and they are all hanging around the 10k mark.

Auto Trader, plus I keep my eye out when driving, 2g's tend to be a bit more due to the fact that they are newer. 1g's however can be found for dirt cheap if you know where to look and get lucky. I was at advanced autoparts picking up an alternator one day and there was a guy BS'ing in there that said he had an AWD he wanted to get rid off all it needed was a gas tank for 500. So I bought it swapped the tanks, cleaned it up and sold it for 2000. Kicking myself for it now because gas prices are so high and I am stuck with a guzzling v8, so I am once again looking for a cheap 1g awd.

It all depends on what you want to do with your car. Most of the fastest 1/4 mile cars are indeed automatic.

That is because an automatic transmission can shift gears faster than you could ever hope to using a clutch and manual linkage. That does not include an air shifter so don't flame me on that one.