#G60 o2j swap manual#

2x Nuts for the wheel end of the Axles, these are one time use only! 12x Bolts for the manual transmission end of the axles, these are also one time use only 1x bottle of blue threadlocker 2x Vertical bolts for the transmission mount (again, stretch bolts!) 2L VW Gear Lube for the 02j transmission Tools: Yes, you will need a LOT of tools for this job Special Tools: VAG-COM from M8, M10, M12 Triple Square bits Clutch Alignment Tool (might come in the clutch kit) Transmission Jack (will make it MUCH easier than bench pressing the puppy in and out!) Continuity meter (normal VOM will work) 30mm 12 point socketįirst things first, don't try this unless you've got a flat area, jack stands, wheel chocks, and some help! Preperation: Loosen the front lug nuts (they're acutally bolts, so remember DON'T REMOVE THE BOLTS!!!) Jack the car up, support it, and chock the wheels remove both front tires Have someone step on the brakes while you complete the following: Remove the 30mm 12 point nuts holding on the axles to the wheel hubs.

What we need Electrical: '53' relay (horn relay) Red 3M crimp butt connectors Reverse switch (should come with the transmission) Clutch Switches (there are two on the clutch pedal, make sure you get the two brackets) Mechanical: Shift Linkage, complete with shift boot and shift knob, there are two boot types, so it might take two tries before you've got it right Clutch Pedal Transmission from a TDI (if yours is a 2.0 or 1.8T, try to get one from a TDI, it's got better gear ratios) Manual Transmission Starter (the automatic one won't work) Manual Transmission Axles Dust Tins from the Engine (it's between the transmission and engine, and comes with two pieces) All of the nuts and bolts that were removed from the junkyard New Stuff Needed: 1x New Clutch (might as well throw in a G60/VR6 from or ) 1x sigma5 short shifter (the OEM shifter won't clear the power steering line). we're also going to adapt one of the brackets from the automatic wiring harness to support the power steering line. We're going to adapt the existing harness for clutch cancel, cruise, and reverse switch later on. Since there are all of these differences, we're not going to use the transmission, transmission computer, axles, Starter, chunks of the wiring harness, park neutral relay, and probably a bunch of other stuff that was left out just because we're a bit lazy, or didn't take that photo. not there (Duh!) Starter Wiring Harness (Duh!) Park Neutral Relay Notable DIfferences The automatic has a different: Coolant pipe Power steering line Injection Pump Axles Transmission Computer (the manual doesn't have any wires, other than the speed sensor and the reverse switch) Transmission (Duh!) Shift Linkage (Duh!) Clutch Pedal. It's for the budget conscious, or for the green, or for those who want a little more power. This one is specifically from a 2001 Beetle TDI ith occasional shots from a 2003 Jetta TDI. Who is this for? This instructable is for owners of any Mk4 VW Golf/Jetta/Beetle. This is my first instructable, Thanks to everyone who voted for me in the Epilog Challenge! I don't think I'm going to win, but hey it's not a bad try!

and you want to save some money, and get better economy to boot. 5) Your automatic transmission just died. 3) The automatic TDI only gets about 35 MPG real world, where the manual is capable of delivering a prius challenging 50 MPG. and at $4500 used, it's expensive junk 2) the 02j 5 speed is not junk, and at $600-$1000 used, you can save a lot of money converting. why do you want to swap? 1) the 01m automatic transmission is junk. Note this is for the TDI only, the 1.8T and VR6 are similar, but wiring, and programming are almost 100% different.

G60 o2j swap