manual gearbox swap

[Gavinda]

I have decided to start collecting parts for a manual gearbox swap , although I am not in any rush to swap it over. any advice from those that have done this is welcome, or suggestions of jobs worth doing while engine is out.

here is my list so far with prices and suppliers:

01e gearbox from early s4 or rs4. local breaker has an rs4 box (500-800)

spacer plate to fit box to engine US specialist spacer plate with clutch flywheel kit ($2000) - bit pricey for a spacer plate and I already have a clutch on the shelf
flywheel
clutch (helix triple plate 1000)

JHM 01e rebuild kit with updated 1-2collars +carbon synchros (695)

software to run with manual box' (034 motorsport )



metal coolant fitting to replace leaky plastic ??(heard this mentioned a few times )

[simonpoulton]

There are quite a few things to do whilst you have the engine out - how many miles has the engine done?

Basically anything around the back of the engine is a pain / impossible to get to without the engine being out, and there are a load of jobs that are so much easier with it out. Including the oil cooler pipe you mentioned (buffkin they call it!)

Have a read back through the threads in the forum if you have a few hours and you get a great feel for the jobs that come up

[bam_bam]

I have decided to start collecting parts for a manual gearbox swap , although I am not in any rush to swap it over. any advice from those that have done this is welcome, or suggestions of jobs worth doing while engine is out.

here is my list so far with prices and suppliers:

01e gearbox from early s4 or rs4. local breaker has an rs4 box (500-800)

spacer plate to fit box to engine US specialist spacer plate with clutch flywheel kit ($2000) - bit pricey for a spacer plate and I already have a clutch on the shelf
flywheel
clutch (helix triple plate 1000)

JHM 01e rebuild kit with updated 1-2collars +carbon synchros (695)

software to run with manual box' (034 motorsport )



metal coolant fitting to replace leaky plastic ??(heard this mentioned a few times )

- A6 gearbox mounts
- A6 prop and driveshafts
- A6 slave to master cylinder
- A6 pedal box (but if I were you I'd go aftermarket)
- Custom starter (such as a race starter with an offset gear)
- Lots of custom wiring; rewire the starter to work without autobox relay, wire in clutch
- Getting the ABS, engine and gearbox ECUs to be happy with no auto tranny
- I would suggest cryogenics on 5th and 6th gears if you're planning on biggish torque


Good luck!

[jockthedog]

viewtopic.php?f=2&t=120012&start=15

....has a bunch of things people have suggested to do while the engine is out on mine.

If you need a hand with the 01E gearbox JHM upgrades, I've done a few of those

[bam_bam]

If you need a hand with the 01E gearbox JHM upgrades, I've done a few of those

Yep, yes please, that'll be me then. What can you do? I think it's an awful gearbox. It's like trying to stir a create of watermelons with a crowbar.

[jockthedog]

If you need a hand with the 01E gearbox JHM upgrades, I've done a few of those

Yep, yes please, that'll be me then. What can you do? I think it's an awful gearbox. It's like trying to stir a create of watermelons with a crowbar.

I can do anything with these boxes. I've fixed a couple of dozen 1/2 collar issues and plenty of others.
My avatar pic is of the 5th and (special, longer) 6th gears, which were superfine polished.
I have the special tools (VAG385) to allow me to reshim the box if you change shafts/gears/bearings. Handy for combining two iffy boxes into one good one.
I've also modded many S4 center diffs to get a 4:1 split.

Don't know if I've ever removed a crowbar from a watermelon tho.
I've certainly stuck a bottle of vodka INTO a watermelon.....with the Great Yarmouth police there to help, but that's another story

[Gavinda]

Thanks for the guidance. The car has done 115k miles, but the engine was out a couple of years ago for a gearbox so may have had some bits done.

whereabouts are you located jock, great yarmouth? I'm close to leeds, certainly interested in your work.

[jockthedog]

I enquired about cryo-hardening the gearset in the 01E box - 175+vat.

VERY good value!

[jockthedog]

Thanks for the guidance. The car has done 115k miles, but the engine was out a couple of years ago for a gearbox so may have had some bits done.

whereabouts are you located jock, great yarmouth? I'm close to leeds, certainly interested in your work.

haha no that thing in GY was 30 years ago, almost to the day.
I'm just south of edinburgh, so not much further from you than Norfolk.
And much nicer