2003 RS6 Build thread

[jolio1994]

Reminds me of my B3 (Although I only opted for a 2.2T). Theres actually a dude on TheProjectPad that's swapping in an S8 4.0T Engine and transmission into his Coupe!

20180708_174853 by Joel Francisco

Yea, that cap was a bitch, I had to drill the I.D. to 21/32, tap it out for 3/4"-10, and then ram and bottom the bolt out to push it out.

With that the Flywheel, Clutch, and Pressure Plate are installed. Waiting on a new Throw Out Bearing, as I broke off one of the clips that secures it to the clutch fork.

20190313_100819 by Joel Francisco

Also took apart the rest of the A6 and had it picked up today.

20190312_112351 by Joel Francisco

[Rune Holen]

Hi

Nice Project!! I put the same gearbox (01e) with the same engine (bcy) in a 94' Audi 80 competition a few years ago. Without damage anything in the engine room. I will follow this Project:)
Now that you have removed the ''flywheel'' just remember to remove the ''cap'' that are knocked in the end of the crank. I do not know what this adapter plate are, that was mention here?
(sorry for my bad Norwegian/English)…

Good Luck

Fcuk off! MOAR of this car, NEOW!

This is Bam's way of saying " He likes your car and would like too know more about it "

Thanks, but I cannot destroy this thread with my project ( 6 speed 01e from v8, rs6 engine built to singel turbo, tilton clutch etc, breaks about 700hp1100nm, audi rs2 driveshaft and breaks )

[jolio1994]

Well I guess it's been long enough! Finally got my replacement throw out bearing from SPEC.

Today I went ahead and installed it on the 01e, lubed up the input shaft, tightened down the clutch fork.... anddddd matted up the transmission to the engine. Torqued the bigger bolts to 40 ft-lbs and smaller ones to 30 ft-lbs, should be enough. I'm worried about cracking the adapter plate so for now it should do. Lets see, what else... the oil cooler is back on, I'm running into the same issue I did last time and it feels like the housing is going to crack on the rear bottom (smallest bolt). I can't even get it to click at 15 ft-lbs, it just keeps going. So I'm holding off on fully installing that for now. Just have to bend the oil/coolant lines going into the oil cooler and I should be set to fully install the exhaust manifold back onto the turbo, then it's time to install into the RS.

I know one of the write up's I was reading stated to use the RS6 transmission mounts instead of the B5 S4/C5 A6 ones, included a picture of that as well to show the minimal, but noticeable difference between the two.

More tomorrow...

20190323_195833 by Joel Francisco
20190323_220626 by Joel Francisco
20190323_220637 by Joel Francisco

RS6 on left, S4/A6 on right
20190323_210827 by Joel Francisco
20190323_210821 by Joel Francisco

[jolio1994]

Some late night modification. Just need to try and buff out the small scratches.

[jolio1994]

So here's what's up. I usually only work 06:00-2:30 on Saturdays, but yesterday I had to stay and didn't leave until 11:00 PM. So, aside from rolling the car into the garage Saturday night, nothing happened.

2019-03-31_11-35-45 by Joel Francisco
20190330_233243 by Joel Francisco

Started to tear into her this morning; jacked the front up, and went to install.

2019-04-01_12-01-09 by Joel Francisco

My recommendation, as this has always worked beautiful for me and today was no different...

-Install the entire shifter assembly outside of the vehicle, that way once installed, you don't have to fiddle around too much in the car and feeding the rods through to rubber boot as well as bolting them to the shifter. I was able to quickly make a tiny adjustment to both shifter and stabilizer, and then bolt it right up the the car.
-Keep the transmission and engine mounts slightly loose, just enough to turn them and wiggle them into place, then when in the car, tighten all the way.
-Bolt the transmission down first, that way you'll know there the engine mounts are going to sit. Mine ended up not moving and are in the center holes.
-Bentley says to loosen the rear part of the front subrame and place 2x4 blocks to create more clearance, I highly suggest this; also loosen up the front 3 bolts that the engine mounts bolt onto. It makes installing the engine mounts easier as well as lowers the entire front subframe more than enough to get the engine and transmission in there.
-While installing the engine/trans, get the trans to clear the subframe first, THEN install the downpipes. They sit about 6 inches lower than the transmission so it's just easier to do and not have to worry about downpipes clearance (IMO)

The SteveKen Kit is awesome. The average DIY'r isn't going to take the block out have it machined or swap all the parts over to a S6 block.
A- That's a lot of money to invest.
B- I said average. I don't have the resources, and time.

And this is my review if you will for other's out there wanting to go manual. Whether it be you're just tired of the auto trans or have a failing auto trans, this kit will get you up and going in no time, no hassle. I had a few question prior to purchasing because hey, there really isn't anybody out there that's documented it save a few. He answered all my question I had, I paid the man and 10 days later I got everything. The kit came with very clear installation instructions, and went on no issues with all the supplied hardware.
There was talk that it moves the engine up about an inch or so, and therefore, needs to use the the front most mounting holes for the engine mounts. I didn't find that the case and everything fell right into place in the stock location. My only concern throughout this entire thing swap wise would have to be the tq specs for the bellhousing adapter bolts. Some clarification on that would be helpful. I torqued the 16mm bolts to 40ft-lbs and the smaller ones to 30 ft-lbs, main concern being cracking the adapter plate. But with that being said, I believe all is well. everything's tight so time will tell. 100% happy as hell with how everything came out, and if I run into any issues, I will be the first to say (Including right now for the record) that it has to be an user error on my end. The kit fits perfectly, and I can't thank you enough for dedicating your time into making this a feasible option for the rest of us.

20190331_152202 by Joel Francisco
20190331_152144 by Joel Francisco


She's in there! Joel's Happy...
20190331_225937 by Joel Francisco
20190331_225848 by Joel Francisco


[youtube]https://www.youtube.com/watch?v=5OuMkwENe1c[/youtube]

[Classik]

Looks good, great job! I'm also considering a swap at some point, but since I've just installed a new (refurbished) ZF box, we'll talk about it in 150,000kms..
Now, more importantly : how does it feel ?

[jolio1994]

Shifter feels awesome! That's about it, clutch is about 70% bled. Need my wife for the other 30% unless you guys have a better clutch bleed procedure that can be done by myself.

Car's back together save a few misc connectors. I may have damaged the wheel bearings when I removed the axle, put the car on the ground, and rolled out out/into the garage. There's a lot of play now. Hoping this is normal and when I put the axles in it'll tighten them up. Can anybody take a picture of the routing/wiring of the 12v panel behind the secondary firewall under the coolant tank. I don't remember...

20190401_181149 by Joel Francisco
20190401_180908 by Joel Francisco
20190401_180927 by Joel Francisco


The panel in question. Going to remove the corrosion prior to installing wires.
20190401_165355 by Joel Francisco

[benh999]

It’d be worth running a boost test on your intercoolers before you put the front end back on Joel... they have a nasty habit of leaking from the cores...

[Classik]

Is that what you're after? I've cleaned mine since I've taken the photo...

[jolio1994]

That's exactly what I'm after thanks! I'm still having issues with 2 more wires that are on that harness (They're not in the picture).

[jolio1994]

Made sure to fill it up with oil first haha. Should run a lot better tomorrow once the Intercooler piping is all tightened down and MAF's a connected. Huge thanks to everybody that's helped me out.

https://www.youtube.com/watch?v=h-aOO_vQ_OA

[jolio1994]

Well, another great day! I couldn't see where the coolant was coming from so I took the engine/trans out... 3 hours to remove the axles, driveshaft, shifter, and engine/trans, take it out of the car, and set it on a dolly. I'd say I'm getting pretty good at it.

Anyways, there are two coolant lines in the rear of the engine that split off into braided lines, then to the turbos. The one on top burst at the rubber hose right before the T. Goes into the engine. Judging by the lines, I believe its item #26. So I'll have a blast finding a replacement, unless I can find one from a part out.
20190406_171241 by Joel Francisco
20190406_201125 by Joel Francisco
20190406_202308 by Joel Francisco
20190406_202933 by Joel Francisco
Screenshot_20190406-231040_Chrome by Joel Francisco

[jolio1994]

Alright, new coolant return hose was recieved today. Installed with the addition of the intake manifold and all related parts.

Seeing as the car is outside and that's were the install will happen, now I just need to wait for a nice sunny day.
20190415_201716 by Joel Francisco

[jolio1994]

Well dang it's been a while.

I went ahead and fixed the coolant leak and reinstalled the engine last week. Got the entire thing put back together and it was running great! Until I tried to drive it.

Car wouldn't go into gear, yay. Took the engine out last Saturday, separated the engine/trans on Sunday; come to find that the Spec clutch was binding. Overnighted a Ringer Racing Stage 4+ Clutch on Monday, installed it and bolted the trans back onto the engine Tuesday.

Wednesday I installed it into the car aswell as the driveshaft, CV axles, and a few other odds and ends.

Later today when I get off work I'll bleed the clutch and try and roll it under it's own power. If that works I'll be good to re install the rest of the front end.

Cheers!
2019-04-24_06-53-50 by Joel Francisco

[jolio1994]

Straight Pipes + Garage = Awesome?
[VIDEO]https://www.youtube.com/watch?v=_wn79nvd5jE[/VIDEO]