2003 Audi A4 Avant - 5 speed manual swap

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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by Mikewire »

No pictures, but I have the rear diff in. I got the drive shaft installed and everything bolted up and every bolt in the rear is all torqued to spec.

I just got the downpipe installed and the axles in and loosely bolted up, so all that's left is to get those bolts torqued, then get the starter back in, the exhaust back under the car then onto wiring all the switches and use VCDS to reprogram the TCU, ABS, cluster and ECU.

Then I can start it and see it everything works.

I'll post pictures in the next update.

Update, here's a pic of the rear diff, fluid leaking from the vent after I dropped it off the jack and it landed upside down...

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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by MT-Getto »

Driving it this weekend eh? Nice work!
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Mikewire's Audi A4 Avant 5 speed swap

Post by sneakyboy1 »

Dude you are cruising through this swap!!
Awesome!!!
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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by Mikewire »

Ok, Friday night: starter installed, exhaust back in and mated to the downpipe and axles installed. Bypassed the neutral start and reprogrammed the ECU and got it to start and run.

Saturday: Axles torqued to spec, and ECU pin #39 was tapped, run to the clutch switch and programmed. Starting with the ABS module, which was very cranky at me for trying to reprogram it, I eventually got to the point where I could code it as a manual. Then the engine module, then the cluster.

Here's a shot of the auto tranny out of the car and on my shop crane, with the wiring harnesses hooked to the trans and the gear selector sensor. I needed to do this so I could reprogram the ABS module without getting auto trans and ECU errors. The module(s) cannot be programmed if there is a fault code.

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Pulled out the rest of the auto bits like the boost pump sensor and the booster pump, wired up the clutch and brake switch too. I had a bit of problem with both the brake and clutch switches not working, so I went ahead and just replaced both since they really aren't that expensive and I could source them locally. Reverse lights also wired up and the remaining bits of the auto engine harness I capped off and zip tied to the main harness on the drivers side frame rail.

Buttoned up the center console and got everything back together in the cabin.

Sunday: Took it out on the maiden voyage to a small GTG. Worked fine but the clutch switch was not working. This is when I went and was able to find a switch locally and swapped it out in the parking lot. MUCH better!

Drove it around town and went to a familty birthday party, then drove it home. Flawless! Until I hit the car wash lol, I had an ECU screw not quite tight, so a splash inside the footwell :laughing: All good, it's snug now.

Cleaned up the garage a bit and wiped down the interior a little. All done, seems strange that it really didn't take all that long, and I had every part thanks to the guy in Buffalo, NY who shipped it all. In return I'm sending him a thank you package with some fun bits and an auto motor mount for a buddy of his. :thumbsup:

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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by Jd3 »

It should speak for itself
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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by padroB5 »

that is AWSOME!!! congrats on it an going to gether smothly. i bet shes happy to lose alllllll that weight lol. cant wait to see it in person!
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Mikewire's Audi A4 Avant 5 speed swap

Post by MT-Getto »

Great work!
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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by BigSkyGLI »

Well done Mike! Must be like a new car!
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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by Mikewire »

Thanks guys, yeah it's strange and very nice all at the same time :beer: :thumbsup:

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Re: Mikewire's Audi A4 Avant 5 speed swap

Post by uberaudi »

Damn that is awesome, you do quick work! It puts bad ideas into my head though...thanks
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