2001 Allroad Rehab

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Re: 2001 Allroad Rehab

Postby Mikewire on Oct Tue 11, 2016 9:11 pm

Quick update, I ended up ordering the full swap kit with driveshaft and the reverse harness. It should be in transit here soon, I just got an update today from Scott about which terminal it will be delivered to. With any luck I'll have the swap done by the end of the month and have another swap project under my belt.

Next year I want to head to Colorado for Camp Allroad: https://www.campallroad.com/

2015 Audi Q5 2.0T Premium Plus
2005.5 VW Jetta TDI 5 speed
2001 Audi Allroad Quattro 2.7TT 6 speed manual swap
2001 VW Beetle 1.8T GLX 5 speed
1992 VW Montana Green GTI
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC

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Re: 2001 Allroad Rehab

Postby kevin286 on Oct Thu 13, 2016 12:38 am

Nice! There's some piece of mind to be had ordering a kit from a reliable source like that. Camp all road looks pretty nice.
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Re: 2001 Allroad Rehab

Postby Mikewire on Nov Wed 30, 2016 2:00 pm

Stuff finally showed up yesterday. Got it unloaded and went through it:

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Did order the used clutch kit, but I think it's too worn out, so I'll have to repalce it. I also ordered used axles and driveshaft, but I think due to lack of parts I received the new axles and the driveshaft spacer, to adapt my existing driveshaft to the manual transmission. Not a huge deal, should work OK.

I did not receive the clutch master -> slave line, or the fluid supply line, so I have asked for those. And the extra little mini harness they make was also not shipped or included in the boxes.

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Few pictures of the spacer - pretty nice little machined part!

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Moved the AR into the garage and it's ready for another round of teardown.

More to come soon!

2015 Audi Q5 2.0T Premium Plus
2005.5 VW Jetta TDI 5 speed
2001 Audi Allroad Quattro 2.7TT 6 speed manual swap
2001 VW Beetle 1.8T GLX 5 speed
1992 VW Montana Green GTI
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC

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Re: 2001 Allroad Rehab

Postby kompressorgolf on Nov Wed 30, 2016 6:12 pm

didnt have any wierd issues with the same spacer. The Harness comes from a different car. bellhousing hardware is some different, hope he sent those. the starter ones and theres one on the driver side thats different if memory serves.
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Re: 2001 Allroad Rehab

Postby Mikewire on Dec Mon 12, 2016 11:12 am

kompressorgolf wrote:didnt have any wierd issues with the same spacer. The Harness comes from a different car. bellhousing hardware is some different, hope he sent those. the starter ones and theres one on the driver side thats different if memory serves.


No extra hardware, but from what I understand with this swap, it's all the same. Thanks for the info, and I guess we'll see...

Got it off the ground and pulled the front core, then dropped the rear diff:

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Threw a sticker on the driveshaft just for fun :thumbsup:

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Pulled the TCU module and attempted to recode the modules. All went fine, except for the engine module, which will not take the recode. I'm understanding there's a specific flash that needs to be loaded, and I'll have to handle that later. For now it will drive and go, but I want to get the hardware swap done.

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I appreciate Scott @ AA getting the parts rounded up, and I realize getting used parts can sometimes be hard to get due to supply and demand. However, looking at the used clutch setup that came with the swap I decided that it's not going to work for me. The disc is too worn and the pressure plate looks like it sat outside for a couple of years. I'll store this on the shelf for another day and another car.

So, I had to order a new clutch kit, which I got from ECS Tuning - Valeo has been my pick for clutch kits and SMFW conversions lately, but I picked up a LUK this time. I'll run the DMFW for now, and most likely will be replacing it when it fails.

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From here, I need to raise the motor up and drop the trans. Then I can start to get it back together.

Waiting on some clutch parts, the fluid supply line to the master, and the hardline from the master to the slave. Also need the wiring harness for the neutral safety switch and the reverse lights.

2015 Audi Q5 2.0T Premium Plus
2005.5 VW Jetta TDI 5 speed
2001 Audi Allroad Quattro 2.7TT 6 speed manual swap
2001 VW Beetle 1.8T GLX 5 speed
1992 VW Montana Green GTI
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC

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Re: 2001 Allroad Rehab

Postby 201motels on Dec Mon 12, 2016 2:23 pm

That sticker is going to throw off the balance of the drive line. :laughing: :laughing: :laughing:
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Re: 2001 Allroad Rehab

Postby Mikewire on Jan Wed 11, 2017 11:56 am

Pulled the shift assembly and trim out:

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Old junk :)

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View from underneath is kind of fun!

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Removed the flex plate and this spacer:

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Installed new pilot bearing in the DMFW:

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Installed clutch!

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Now onto the pedal assembly.

I broke the plastic 90 part on the fluid supply line, so I ended up buying some brass replacement parts and made my own:

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I chose to pull the pedal assembly and swap pedals from the A6 assembly to my existing Allroad assembly:

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From outside, I scored the paint around the body plug, this is where the master -> slave line will connect:

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An inside view, give the plug a push and bam, it's gone:

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From two pedals...

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To three pedals!

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Prepped all the misc. parts and reassembled the slave, mounts, throwout and arm, and mounted the shift assembly. I'll remove the shift asdsembly (and mounts) and install it separately, just wanted to mock up the parts and make sure I had everything:

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I did purchase the USP metal slave and braided stainless steel line, which I will replace before installing the transmission. It just showed up after I installed the plastic one. From here, it's time to bolt up the shift assembly, and then install the transmission and bolt everything else up.

2015 Audi Q5 2.0T Premium Plus
2005.5 VW Jetta TDI 5 speed
2001 Audi Allroad Quattro 2.7TT 6 speed manual swap
2001 VW Beetle 1.8T GLX 5 speed
1992 VW Montana Green GTI
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC

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Re: 2001 Allroad Rehab

Postby MT-Getto on Jan Thu 12, 2017 8:11 am

I don't care what the other members here say about you. You do fine work Mike :-)


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Re: 2001 Allroad Rehab

Postby itskmill06 on Jan Thu 12, 2017 12:06 pm

This looks like fun!


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Re: 2001 Allroad Rehab

Postby Mikewire on Jan Thu 12, 2017 3:28 pm

Thanks guys :)

Yeah it's fun, but it's also cold out there and my garage isn't heated. So it's taking longer than expected.

Got this in though, so now I can get that trans installed:

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2015 Audi Q5 2.0T Premium Plus
2005.5 VW Jetta TDI 5 speed
2001 Audi Allroad Quattro 2.7TT 6 speed manual swap
2001 VW Beetle 1.8T GLX 5 speed
1992 VW Montana Green GTI
1972 VW Kombi 9 Passenger Deluxe w/ 2.0L F.I. VWAC

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