Rs6 manual swap! Single turbo sauce

4.2 V8 40v biturbo - 450 bhp
4.2 V8 40v biturbo - 480 bhp (plus)
Bowers155
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Location: Gloucestershire

Re: Rs6 manual swap!

Post by Bowers155 » Sat Jan 25, 2020 9:20 pm

Yet again it’s that time.
Managed to get loads done very little photos because I’ve just been getting on with it...
Managed to get intercoolers sealed (jb weld) found a hole in one so hopefully that holds up
Went to do the chains and they looked fairly new and pads with very little or no wear...
So put the black rocker covers on and set about putting it all back together.
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Today was a good day when all of the hard work became worth it! I drove it for the first time
After bleeding brakes and the long list of other things I’d done I drove it up and down my works yard a few times and double checked all levels. Mainly gearbox becuase the 2.5tdi uses oil cooler.
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Drove it home and done 30odd miles now and chuffed to bits! Completely different car.
Didn’t want to cut the carbon trim to have a gaitor because a better clutch and this:
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I personally love this shifter and think I should suit the car!
So boys and girls no updates from now on untill the new clutch and shifter arrive when I come back from newyork and start the mapping!

Any questions fire away. Loads of information just hard to write every little step!

ian_rs6avant
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Re: Rs6 manual swap!

Post by ian_rs6avant » Sat Jan 25, 2020 9:26 pm

awesome I've just sourced a flywheel and won a doner car today of ebay so I'm.commited to going to manual whilst its stripped!

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Bowers155
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Re: Rs6 manual swap!

Post by Bowers155 » Sat Jan 25, 2020 9:38 pm

ian_rs6avant wrote:
Sat Jan 25, 2020 9:26 pm
awesome I've just sourced a flywheel and won a doner car today of ebay so I'm.commited to going to manual whilst its stripped!

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What flywheel are you going to be using and what is the donar an a6? But what engine?

ian_rs6avant
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Re: Rs6 manual swap!

Post by ian_rs6avant » Sat Jan 25, 2020 9:43 pm

ttv mate for flywheel and a 2.5tdi a6

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Bowers155
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Re: Rs6 manual swap!

Post by Bowers155 » Sat Jan 25, 2020 9:51 pm

Exactly the same as me then! Are you going to use an adaptor or done exactly what I’ve done and not bother? Can add me on fb or Instagram or WhatsApp and I can run you through some bits I’ve found with using this combo...

ian_rs6avant
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Re: Rs6 manual swap!

Post by ian_rs6avant » Sat Jan 25, 2020 9:53 pm

Bowers155 wrote:Exactly the same as me then! Are you going to use an adaptor or done exactly what I’ve done and not bother? Can add me on fb or Instagram or WhatsApp and I can run you through some bits I’ve found with using this combo...
I'll just do what you did I think mate, I've got you on Instagram I'll have a look on fb for you. appreciate that mate


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IchBautAuto
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Re: Rs6 manual swap!

Post by IchBautAuto » Sat Jan 25, 2020 11:59 pm

Bowers155 wrote:
Sat Jan 25, 2020 9:51 pm
Exactly the same as me then! Are you going to use an adaptor or done exactly what I’ve done and not bother? Can add me on fb or Instagram or WhatsApp and I can run you through some bits I’ve found with using this combo...
For us that don't participate in the media mentioned, can you keep the info flowing in this thread too. Pity to leave it half baked and secondly, it helps the forum keep it's head up.
C5 RS6, Milltek and Wagners: B5 RS4 450 + HP: A4 1.8 GP TQS original: 1963 UNIMOG 404:

ian_rs6avant
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Re: Rs6 manual swap!

Post by ian_rs6avant » Sun Jan 26, 2020 11:24 am

hes not mate it's just easier for me to message him on Instagram that's all. mine will be fully documented on my restoration thread too.

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dhali
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Re: Rs6 manual swap!

Post by dhali » Sun Jan 26, 2020 12:04 pm

Great work guys . The achilles heel of the c5 Rs6 will be a thing of the past with these conversions.

bilko1
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Re: Rs6 manual swap!

Post by bilko1 » Sun Jan 26, 2020 6:00 pm

dhali wrote:
Sun Jan 26, 2020 12:04 pm
Great work guys . The achilles heel of the c5 Rs6 will be a thing of the past with these conversions.
I'm afraid it won't, a lot cheaper / easier to fix that's all. Launch a manual a few times and the O1E will <beep> itself if the driveshafts don't snap first. I have hardened gearset in mine and i still won't launch it.
Avus Avant, RNS-E mk2 with sds and Bluetooth, Milltek, Hotchkis, Bilstein, Forge, ITG, A.C.E, Wagner, FBMFSW, MTM.

Bowers155
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Re: Rs6 manual swap!

Post by Bowers155 » Sun Jan 26, 2020 11:28 pm

Now done 150 miles in it and it’s savage even my girlfriend had a smile from ear to ear when I launched it up the road! Bit of and up date picked up some 20” Audi rotors and here she is...
Image
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bilko1 wrote:
Sun Jan 26, 2020 6:00 pm
[quote=dhali post_id=929235 time=<a href="tel:1580036672">1580036672</a> user_id=2447]
Great work guys . The achilles heel of the c5 Rs6 will be a thing of the past with these conversions.
I'm afraid it won't, a lot cheaper / easier to fix that's all. Launch a manual a few times and the O1E will <beep> itself if the driveshafts don't snap first. I have hardened gearset in mine and i still won't launch it.
[/quote]

I’ve done a fair bit or research in 01e’s 4+years of searching the Internet for builds ratios all sorts, anything you could shake a stick at and the 2.5tdi box is pretty bullet proof apart from the normal 1-2nd synchro. However for me... I have a the skill set and all the kit and workshop in order to repair anything when it does go wrong... built a few dsg boxes etc
Couple of things that are on the list are JHM synchro
Cooler works shifter and 4.1 diff mod.
However there is many people running these boxes at around the 1000hp mark and dragging them
As bilko said you will end up breaking them with abuse but they do stand up to it very well...
I’d rather replace a cv joint stripped gear or a synchro over a torque converter or anything automatic related!

I shall let people know what I break and what I replace with if or when it does happen :audibash:

north-star
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Re: Rs6 manual swap!

Post by north-star » Sun Feb 02, 2020 2:23 pm

Great thread, if i keep my one i may look at this route when the gearbox goes if i can persuade my pal who works on my 6 to do it, lol

Mark-RS
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Re: Rs6 manual swap!

Post by Mark-RS » Sun Feb 02, 2020 4:32 pm

Maybe a silly question, but would you have any enthusiasm to do other cars ? People on here maybe ? Obviously not for free !

If so, any ideas on a cost ? As I would certainly be interested !

Bowers155
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Location: Gloucestershire

Re: Rs6 manual swap!

Post by Bowers155 » Mon Feb 03, 2020 3:25 am

north-star wrote:
Sun Feb 02, 2020 2:23 pm
Great thread, if i keep my one i may look at this route when the gearbox goes if i can persuade my pal who works on my 6 to do it, lol
You won’t regret it! If you decided to go this route a few headaches and what not but completely restored my love for the car!

Mark-RS wrote:
Sun Feb 02, 2020 4:32 pm
Maybe a silly question, but would you have any enthusiasm to do other cars ? People on here maybe ? Obviously not for free !

If so, any ideas on a cost ? As I would certainly be interested !
I would consider it but price would be an open tab sort of deal... although the process is the same some steps may take more or less time depending on conditions of parts removing or installing into the car. I’d also need the car delivered to me with all the parts required to do the swap.
I’d like to get mine to a point I’m satisfied with before taking another. In terms of cost it’s going to be mainly down to: clutch flywheel and how much you can get a donor car for.

alfnomad
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Re: Rs6 manual swap!

Post by alfnomad » Mon Feb 03, 2020 9:14 pm

Hi! Great topic! and GREAT CAR!!!

New on this forum... So a little bit about me:
Belgian (usuasly speak french, sorry if mistakes)
Working in IT/Networks
Petrolhead (fan of BBC TopGear& Amazon GrandTour)
Fan of the C5 platform, I used to have a 1.9Tdi AVG, then a 2.5Tdi AKN Quattro MT
And now... A wonderfull S6 c5 ANK
Just one problem... This is a f**** Tiptronic...

So I'am about to do the same as you, ordering this:
https://advancedautomotion.com/shop/pro ... sst385j2o1

at first I was thinking to reuse my old 2.5tdi gearbox... but I was affraid to loose acceleration...
The new gearbox will be in my garage in 2 mounth (boat shipping) whit a high bias custom 60/40 center diff

So I need some advices...

Mainly about the ECU software...
I have a true rosstech hex+can, a chinese Vagcom, and a probably chinese KESS V2
Is it simple to do the changes on the ECU? Can I do it all by myself?
Is it only a firmware flash of the ECU or I have to do the ABS/ESP Module?
If it's hard, is your solution expensive? could you please send me the coordinates of the "guy" who did it to your car??

Thanks a lot and... In french... Bonjour chez vous!

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