2006 VW Jetta BRM TDI DSG to 5-speed manual swap/ conversion

Discussion in 'Mk5 VW Jetta, Sportwagen, and Audi A3 TDI forum' started by pedaltheglobe, Jan 24, 2016.

  1. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    NP. Having cruise control again is awesome. Makes my 8.5 hr drive to Ohio bearable. :nana
     
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  2. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Between the wife and I being sick for the month of January, and the family commitments, my progress has been slow going.

    What's done so far:
    1) Pull transmission
    2) Pull DSG axles
    3) Pull cluster & send manual ECU to be flashed / married
    4) remove DSG Shifter
    5) Install 5sp shifter
    6) Change brake pedal
    7) Install clutch pedal & master cylinder
    8) Install cluster & ECU

    What's left to do:
    1) Replace heater hoses while I have access
    2) Modify wiring
    3) Install clutch
    4) Prep control arms - it's time to replace bushings and ball joints
    5) Install transmission
    6) Rebuild both axles - new boots and regrease
    7) Install Axles
    8) Adjust shifter cables & bleed clutch & brakes (time to change fluid anyway)
    9) Pull control arms
    10) Install control arms
    11) Test drive & check alignment

    Looks like at 2 more weekends.

    Tony
     
  3. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    Almost there. I threw in a dieselgeek short shifter. Much better.
     
  4. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Talk about slow going!

    What's done so far:
    1) Pull transmission
    2) Pull DSG axles
    3) Pull cluster & send manual ECU to be flashed / married
    4) remove DSG Shifter
    5) Install 5sp shifter
    6) Change brake pedal
    7) Install clutch pedal & master cylinder
    8) Install cluster & ECU

    Last weekend:
    9) Replace heater hoses while I have access

    This weekend:
    10) Modify wiring
    11) Rebuild both axles - new boots and regrease
    12) Prep control arms - it's time to replace bushings and ball joints
    13) Pull control arms
    14) Install control arms

    What's left to do:
    1) Remove pilot bearing outer race
    2) Install clutch
    3) Install transmission
    4) Install Axles
    5) Adjust shifter cables & bleed clutch & brakes (time to change fluid anyway)
    6) Test drive & check alignment

    As usual, the pilot bearing is being a major PAIN. Looks like I will have to take my time with a small cold chisel.

    Tony
     
  5. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    Hey Tony,

    You DO NOT need to take the pilot bearing out or replace. It is not used in the manual. I left mine in, it was trashed anyways. The input shaft does not touch the pilot bearing when the transmission is mated to the engine.

     
  6. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    nc73,
    I understand that. I even went so far as to measure and compare the depth of the input shaft. I know it clears the pilot bearing.

    Given that I have most of the pilot bearing out, I feel the need to make sure the remainder of the outer race is removed. I'll give it some time with a cold chisel.

    Thanks!

    Tony
     
  7. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    I tried for a few minutes to get it out myself but like you, I measured and knew it wouldn't be a problem.

     
  8. 2006_jetta_TDI

    2006_jetta_TDI New Member

    Joined:
    Mar 6, 2017
    Messages:
    1
    Car:
    2006 VW JETTA TDI
    Location:
    MICHIGAN,USA
    Mods:
    BOne Stock
    so who has figured the whole thing out, for reverse switch if i have the engine harness off the car with the stick trans can i just put that on the car with the auto trans and that way the reverse switch will be hooked up, and also the wiring for the clutch for cruise, basically u just need it to kill the cruise when pushed, and then not start when not pushed right? or is there more to it thanks guys first time vw owner and I'm going to anttempt this
     
  9. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    Wiring harness from a manual into an auto would just be a pain in the arse. It should solve most of the issues. You can accomplish everything by just following the wiring diagram and not having to swap the harness. It's all in the thread. I have everything working except reverse. It's not hard but I don't need it. No inspection in Ohio.
     
  10. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Finally got the bearing race out. Carbide burr, die grinder and 5 minutes!
    Also found that I need to replace the pendulum mount on the cradle: all the rubber is cracked, if not broken. At least I have access.

    Onward and upward!

    Tony
     
  11. judel

    judel New Member

    Joined:
    Feb 22, 2017
    Messages:
    18
    Car:
    Jetta TDI 2006
    Location:
    Puerto Rico
    Hi,, guys I want to swap my car too. Is a jetta 2006 1.9 TDI with DSG. Where I can find the manual transmission kit?
     
  12. judel

    judel New Member

    Joined:
    Feb 22, 2017
    Messages:
    18
    Car:
    Jetta TDI 2006
    Location:
    Puerto Rico
    Hi guys I want to swap my jetta 1.9TDI 2006 dsg to manual. Where I can buy the complete kit?
     
  13. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    http://forums.tdiclub.com/showthread.php?t=434593
    Dutch auto parts is the cheapest ships from Netherlands. There is one in the USA but 600 more. Otherwise you'll have to find a good deal on forums, if there is any. I got mine for 440 on tdiclub forum but that is super rare and i had to drive to canada to get it. Still way cheaper. Best thing I did was to convert it to manual. If you don't want to deal with the hassle just sell it and get one with manual. Overall it was pretty easy swap for me, did not take very long either.

     
  14. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
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    22
    Car:
    jetta tdi 2006
    Are you all done yet? :D

     
  15. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Almost. All the heavy mechanical is done.
    Left to do:
    Bleed brakes & Clutch
    Adjust shift cables
    Interior

    It may be running tonight.;)

    Tony
     
  16. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    Ah so just the easy stuff left.
     
  17. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Got it running last night!
    Finished off the details today.
    Put 40 miles on the car. No issues! Got an alignment scheduled tomorrow afternoon.

    I'll post some pics of the wiring this weekend.

    Tony
     
  18. nc73

    nc73 New Member

    Joined:
    Dec 22, 2010
    Messages:
    22
    Car:
    jetta tdi 2006
    Nice! Mine shifted horribly the first time because the shifter was so old, replaced it with a dieselgeek and no more misses!

     
  19. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Put about 100 miles on the car, before discovering a coolant leak. Fortunately, it was a slow drip that allowed me to get home without overheating or any other damage..

    The plastic coolant flange at the back of the head leaks when it's got over ~8psi in the system. My best guess is that the o-ring shrank due to exposure to air, since I did not fill up the cooling system right after replacing the heater hoses.

    Tony
     
  20. TonyJetta

    TonyJetta New Member

    Joined:
    Dec 28, 2011
    Messages:
    18
    Car:
    '96 Passat TDI
    Well, it wasn't the o-ring that shrank. It was the gland that holds the o-ring that eroded, reducing support for the o-ring.

    At this time, I have >200 miles on the car and no issues related to the conversion.

    I am hoping to have some time in the next few days to upload pics and details around the wiring.

    Tony
     

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