ETKA screen shots request & A4 B5 gearbox questions...

[s2_wot]

I have a 98 a4 1.9tdi quattro that came fitted with a 5 speed gearbox. I have changed the gearbox, prop and rear diff for items sourced from a 6 speed a4 2.5 tdi quattro.

Old gearbox, 01A (I think), code DGW. Diff Code DAJ. (35:9)
New gearbox, 01E, code DQT. Diff Code DAK (37:9)

The gearbox mounts are different by the looks of it and it also looks like the 2.5 tdi and 1.9 tdi have differing subframes. I decided to go ahead and fit the gearbox and solve this riddle when I get to it.

So what I'd like to see please is the diagrams that show the various subframes and gearbox side mounts?

Will the I4 engine bolt to the V6 subframe if I source one?
or should I modify the existing subframe to take the new gearbox

Any experience of solving the same problem would be appreciated. Google has not been all that useful for me.

Useful link re gearbox ratios:

5 Speed Audi Gearboxes

6 Speed Audi Gearboxes

[andy10v]

Vagcat from a 1998 A4 quattro

http://www.vagcat.com/epc/cat/au/A4Q...19/51/2648137/



Partlist:

transmission securing parts

for manual gearbox / transmission securing parts / left / 4 cylinder:



for manual gearbox
/ DJJ,DJV,DGW, DWR,DWQ,EEP, DTT
1 8D0399113AB

support for transmission
left /
2 N 0147236



allen key head bolt / also use:
M10X30 N 011 560 8 /
- N 0115608

washer
10,5X18X1,6 /
3 N 10027102


allen key head bolt (combi)
M10X35Z1 /
4 8D0399151H

bonded rubber mounting
/
4A N 90315202

washer
10,5X34X4 /
4B N 0230047



shouldered hex. nut, self-locking / transmission securing parts / AM10 left / 6 cylinder:



for manual gearbox
/ DJR,DJS,DSY, DQT,DWM,DWN, FZV
2 N 0147236



allen key head bolt / also use:
M10X30 N 011 560 8 /
- N 0115608

washer
10,5X18X1,6 /
4A N 90315202

washer
10,5X34X4 /
4B N 0230047


shouldered hex. nut, self-locking
AM10 /
5 8D0399113AG


support for transmission
left / DJR,DJS,DWM, DWN
(5) 8D0399107C

support for transmission
left / DQT,DSY,FZV
7 N 0104707

hexagonal head bolt
M10X70 /
9 8D0399151M


bonded rubber mounting
/ DJR,DJS,DQT DWM,DWN,FZV
(9) 8D0399151T

bonded rubber mounting
/ DSY,FZV
8D0399151J

bonded rubber mounting
/
10 431399291


limit stop
/ DJR,DJS,DQT, DWM,DWN
(10) 8D0399291A

limit stop
/ DSY,FZV
(17) 8D0399299C

shield
left / DSY,FZV
(18) N 90724601


hexagon head bolt (combi) / transmission securing parts / M6X22 right / DSY,FZV

for manual gearbox
/
4B N 0230047


shouldered hex. nut, self-locking
AM10 /
4A N 90315202

washer
10,5X34X4 /
7 N 01047310

hexagonal head bolt
M10X75 /
9 8D0399151M



bonded rubber mounting
/ 6 cylinder: DJR,DJS,DQT, DWM,DWN
(9) 8D0399151T


bonded rubber mounting
/ 6 cylinder: DSY,FZV
10 431399291




limit stop
/ DJR,DJS,DJJ, DJV,DGW,DWM, DWN,DWR,DWQ, EEP
(10) 8D0399291A

limit stop
/ DSY,FZV
12 8D0399108R




support for transmission
right / DJR,DJS,DWM, DJJ,DJV,DGW DWN,DWR,DWQ, EEP,DTT
12 8D0399108AD

support for transmission
right / DQT,DSY,FZV
13 N 90331603




allen key head bolt
M10X40 / DJJ,DJV,DGW, DJR,DJS,DWM, DWN,DWR,DWQ, EEP,DTT
(13) N 0147236


allen key head bolt
M10X30 / DSY,DQT,FZV
- N 0115608

washer
10,5X18X1,6 / DSY,DQT,FZV
16 8D0399151J

bonded rubber mounting
/ 4-ZYLINDER
17 8D0399300K


shield
right / DJJ,DJS,DWR, DWN,DTT
(17) 8D0399300M

shield
right / DSY,FZV
18 N 90724601


hexagon head bolt (combi) / subframe / M6X20 6 cylinder / DJR,DJS,DSY,





25 8D0399313AL


subframe
4 cylinder 6 cylinder / DQT,DWM,DWN, FZV DJJ,DJV,DGW, DWR,DWQ,EEP, DTT DRJ,DJS,DWM, DWN
(25) 8D0399313AL



subframe / F 8D-W-080 001>>*
6 cylinder / DWN DRJ,DJS,DWM, DWN
(25) 8D0399313BH

subframe
6 cylinder / DSY,FZV
(25) 4B0399313CJ

subframe
6 cylinder / DQT
(25) 8D0399313BA


subframe
4 cylinder / DJJ,DJV,DWR, DWQ
(25) 8D0399313BK


subframe / for sports-type running gear
4 cylinder / PR-1BV/ODY;: DJJ,DWR
(25) 8D0399313BA


subframe / F >> 8D-W-130 000*
4 cylinder / DGW
(25) 8D0399313AQ


subframe / F 8D-W-130 001>>*
4 cylinder / DGW,EEP,DTT
26 8D0399419C


bonded rubber mounting / F >> 8D-W-080 000*
rear / DQT DJR,DJS
(26) 8D0399415D



bonded rubber mounting / F 8D-W-080 001>>*
rear / DJR,DJS,DWM, DWN
(26) 8D0399419E

bonded rubber mounting
rear / DSY,DTT,FZV
(26) 8D0399419D


bonded rubber mounting
rear / DJJ,DJV,DWR, DWQ
(26) 8D0399419D


bonded rubber mounting / for sports-type running gear
front and rear / PR-1BV;: DJJ,DWR
(26) 8D0399419D


bonded rubber mounting / F >> 8D-W-080 000*
rear / DGW
(26) 8D0399419D


bonded rubber mounting / F 8D-W-080 001>>*
rear / DGW,EEP
27 8D0399415D


bonded rubber mounting / F >> 8D-W-080 000*
front / DQT DJR,DJS
(27) 8D0399415E



bonded rubber mounting / F 8D-W-080 001>>*
front / DJR,DJS,DWM, DWN
(27) 8D0399419E

bonded rubber mounting
front / DSY,DTT,FZV
(27) 8D0399415E


bonded rubber mounting
front / DJJ,DJV,DGW, DWR,DWQ,EEP
28 8D0399541B

support
left /
29 8D0399542B

support
right /
30 N 90758301

hexagon head bolt (combi)
M8X25 /
31 N 90823501

hexagonal head bolt
M12X1,5X110-SV /
32 N 90663001

bolt,hex.hd.with shoul.(combi)
AM10X70-SW18 /
33 N 01155811

washer
8,4X15X1,6 /
34 N 01024016

hexagonal head bolt
M8X20 /
35 8D0399403A

brace
/ DSY,FZV
36 N 90630503

hexagon head bolt (combi)
M10X22 / DSY,FZV
37 N 10286102

[s2_wot]

Thanks Andy, drivers side one looks like it'll be fine. I'll have to sort something out for the passenger side so I can use the existing subframe.

[Sleeper_Avant]

6 sp conversion in the A4 will require quite a bit to swop over

and the engine bolts to the ARB mounts not the subframe, so yes it will fit, worst case get ****rat 1.9 6sp ones but i know they will be fine

[s2_wot]

6 sp conversion in the A4 will require quite a bit to swop over

and the engine bolts to the ARB mounts not the subframe, so yes it will fit, worst case get ****rat 1.9 6sp ones but i know they will be fine

All done now except for the gearbox mounts and to fit the prop.

I hadn't looked really closely at the engine mounts so my bad, I'll have to get a better look when it stops raining.

Are you saying I should get the subframe from a 6 sp passat or the mounts from a 6sp passat will go onto my subframe? Sounds viable.

I've been sketching mounts that would do the trick but would need to be fabricated. Off the (scrapyard) shelf would be cheaper and easier.

[Sleeper_Avant]

A4 or passat 6sp will be good for the g/box, this doesnt leave a lot of space for exhaust mind! i had to make do with a 3inch downpipe with my TDi drivetrain.

my A4 was a 2.5tdi and i had a 5 cyl mounts like up no problems (but not fit due to height) V8 mounts line up, and V6TT lines up, so i think they use the rollbar as a gravity centre for the engines, all engines! Which is very sensible as i used 1.8 non turbo mounts from a breaker lol

i have a 6sp cradle here if you need pics (will be crap pics, but pics non the less!)

[s2_wot]

Go on then, get the camera out please

I just contacted the guy I got the gearbox off, he sent the subframe to the scrap merchant with the shell

Just to clarify, 6sp passat or A4, 2wd and 4wd?

Thanks.

[arazvan2002]

Hello
I will be in the same situation in the near future. I have the oportunity to change my transmision from A4q 1.9 tdi AFN 98' with 6sp from A4q 2.5 tdi V6 98'. I will get the gearbox and rear differential. I have to fabricate a propeller shaft (maybe one piece). For the left side mount I think I can weld support like on the right side to use my subframe and gearbox's mounts.
I have already a modified clutch 1Z SMF and S2 240 upgraded kit and some engine modifications. I hope I can use the same starter to fit the flywheel. Do I need a spacer or something to fit the gearbox? The 00' ATJ quattro has a spacer with the 6sp gearbox? I think no. maybe is used with V6 engines because they have a shorter block.
For the propeller shaft I have a C4 avant quiet long one. I'm thinking to cut it and make a one piece PP. Also I can search an ATJ quattro 6sp prop...

S2_wot please come back with some pictures, information. I will help me a lot.

By the way....very nice forum. I found a lot of information about audi cars, other than S2 cars wich is great, regarding the name of the forum.

[andy10v]

Any mods to get the 1z flywheel and the s2 clutch to work?

Could the gearbox spacer you mention be the same as the s2, needed for duel mass flywheel, but not for single mass?

What else have you done to your AFN?

[arazvan2002]

The 1Z FW is flat, so it needs new holes to match the bigger pressure plate. the job was done 2 times. First by me in my garage with simple tools, I measured and drilled the flywheel. It was running fine till I broke the spring inside the PP after some continuous stress on the clutch. Second time, I found a guy in Hungary who prepares cars for drift, drag..etc and he has access to some workshops with experience in preparing racing clutches, gearboxes...etc. He did the same thing like me (drilled the FW) and after that he sent the entire kit to a professional workshop to repair the PP and balance the hole thing. Also he changed the friction material on the disc with kevlar type. You will see some big holes in the FW. Are made for balancing. You can see also that the 1z FW + S2 kit has the same thickness as the original DMF AFN 228mm so no spacer to convert (in this case).

The other modifications are described a little in "my garage section" , a link bellow.
The car is estimated by the guy who made the ecu soft to 150-160hp, 340-360NM. I never measured this because I prefer to do something else with that money. The dyno for 4x4 is very expensive, like 150 euro. Is the difference that I should pay for the 6sp transmission. Is a little faster than A3 2.0 tdi 140hp, 8P.

http://www.s2forum.com/forum/dto_gar...ehicle_id=1924

[andy10v]

Ahh, I like the flywheel mod

That looks like quite a nice fun/economical setup.

Is that a seat front lip?

What software/who sorted the ecu for that setup?

I have an a4 1.9tdi quattro saloon in silver, and I have to say your car is giving me bad ideas

[arazvan2002]

The guy who made me the clutch can make from 0 new flywheels, also to fit the other S2 kit, for dual mass or this one. He also repaired few Southbend toasted clutches
Or you can use this FW with the RS, or AVF clutch, or other 240mm clutch for DMF. The 1Z Fw is cheap, but the modification costs some, the S2 kit also... I supose you have same gearbox like me, DGW 5speed.

http://www.advancedautomotion.com/pr...f849aa03f5d0cc


The software was made by a guy from Poland from ecuconnection forum. Rookie. He sent me the 2 bin files each revision and I flashed them to EPROMs,fitted to the car and tested few times,logs, with different setting and fine tunning.
Yes, is a Cupra lip spoiler. I liked the idea from my colleagues from www.clubaudi.ro.
Like my car is giving you ideas, many other cars are giving me more ideas also ))))) The cars are a bad habit shame that I don;t have enough money to spend on it.

I don't know if you know or you were interested till now but you can find a lot of informations on forums.tdiclub.com
http://forums.tdiclub.com/forumdisplay.php?f=13

[andy10v]

Cool, thanks for the clutch info.

I have the stock 5 speed box fitted, have a damaged 3.89 6 speed in the garage, possibly for the future.

I have read a bit on the ecu connections forum (was for early motronic info) , will do some more reading though.

My a4 was bought to save money for the S2, but I keep wanting to mod it

Nice A4 daily, 200bhp and 50mpg (base car was a 110 1.9tdi)
http://audisrs.com/about22005.html&p...uning&start=45

170pd a4 turbo
11mm pump plunger
0.260 injector tips
1 RS4 side mount intercooler
3 bar map sensor
Cut the precat out of the downpipe
Milltek catback
Helix clutch kit

(1.8t flywheel)

I have been reading tdi club, just so much info to sift through at the moment, as I have almost no diesel background information.

[s2_wot]

I have a drawing for a left side mount I had fabricated. I will post photos next week.

[s2_wot]

Lockable rear diff from an s2 ratio is correct.