NOLA Speed and Style

Author Topic: 2002 TDI Wagon 5-speed swap  (Read 1375 times)

November 09, 2016, 12:04:44 am

Millennium Falcon

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2002 TDI Wagon 5-speed swap
« on: November 09, 2016, 12:04:44 am »
My Friend and I spent all day on the road picking up my new toys.

Project car) 2003 Jetta GLS TDI Wagon 165k bad auto tranny, Light front end damage.

Donor car) 2001 Jetta TDI Sedan, 135k good engine, good 5-speed, bad front engine damage.

They both have front end damage but the wagon is way nicer and really only needs a hood. the sedan has a good hood.....so let the swapping begin. Both run and drive but the wagons auto tranny is toast. SO the plan is to swap the 5-speed into the wagon. and the hood will get swapped and painted. So far my total investment for both cars is below. I will try to add pictures and prices as I go. Both cars are filthy inside and out and out. Detail will come later.

2003 wagon $600
2001 Sedan $1200
Fuel $85
Notary $30
Burger King $15
Friend with a trailer...... Priceless!

Total Thus far -$1930

+

OBDeleven $59.99




Reply #1November 09, 2016, 07:34:28 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #1 on: November 09, 2016, 07:34:28 am »
It wont let me post IMG codes from photobucket???? How are you guys posting pictures on here?

Reply #2November 09, 2016, 07:45:49 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #2 on: November 09, 2016, 07:45:49 am »
I think I figured it out! I got all the parts I needed off of my donor car..... I will also now have  a spare ALH engine with 135k sitting under my work bench just in case!



















« Last Edit: November 09, 2016, 07:50:37 am by Millennium Falcon »

Reply #3November 09, 2016, 07:52:16 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #3 on: November 09, 2016, 07:52:16 am »
This car was hit in the front so pulling the engine was much more of  a pain than anticipated. There wasn't much room! The saws-all had to make an appearance.

Reply #4November 12, 2016, 10:11:50 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #4 on: November 12, 2016, 10:11:50 am »
I pulled the auto tranny from the wagon last night. I think its pretty much ready for re-assembly. I'm waiting on my flywheer/clutch to get here. I still need to pull the auto shifter....it was 1:30am when I got the engine out last night so I was saving that for another time.










Reply #5November 15, 2016, 07:48:27 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #5 on: November 15, 2016, 07:48:27 am »
I got the new RMS installed last night... then I put the flywheel/clutch/pressure plate installed. The plan is to get the tranny in tonight and also swap the power steering line over from the 5- speed car.

Reply #6November 16, 2016, 01:27:02 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #6 on: November 16, 2016, 01:27:02 am »
Growler......I took your advice. I installed my #21 SMF and sachs clutch last night. Tonight I installed the tranny, hooked up and adjusted the shifter cables, installed the axles and put new rotors and pads on. the car is pretty much ready for wiring.

Reply #7November 17, 2016, 09:05:28 am

theman53

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Re: 2002 TDI Wagon 5-speed swap
« Reply #7 on: November 17, 2016, 09:05:28 am »
Interested to see the pedal and shifter part of the swap

Reply #8November 18, 2016, 04:36:56 pm

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #8 on: November 18, 2016, 04:36:56 pm »
Sure I will post some pictures of that for you. The trans and shifter are  installed and adjusted. I have the pedal and assembly ready to go in, I just wanted to finish the wiring first since its so cramped working under there. I am just going to stick with the auto brake pedal for now. I have a manual pedal in my parts car but had a lot of trouble removing it. I have seen many people use the auto BP with no ill affects and I have more important things to finish first.

Reply #9November 18, 2016, 04:37:11 pm

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #9 on: November 18, 2016, 04:37:11 pm »
I have pretty much everything wrapped up. all the nuts and bolt are put back together except for the clutch pedal.... I wanted to finish the wiring first. So last night I started to attempt the wiring. It went pretty well. I think I got it all right.... (fingers crossed) All I have left is the final step at with the cruise control. I have the clutch switch wired, I have the TCU removed and the yellow/red wire from the clutch switch to the TCU to pin #19 ready to remove and install it into #66. Is it really that simple? I have the large ecu plug torn apart, and noticed that my #66 pin has no wire in it, so do I just remove #19 and pop it in #66? one of the builds i was using instructions from said to "remove the pin at #19 & #66. I just wanted to make sure I'm doing it right.

Reply #10November 19, 2016, 01:43:12 am

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #10 on: November 19, 2016, 01:43:12 am »
Well So far so good. I got everything back together and fired the car up.... CLutch cancel switch works. Reverse lights work, Speedometer works, clutch works. and I can honestly say OBDeleven is really cool! I used it to change my engine code for the manual trans. It also has many really cool features I cant wait to try. I havent had a chance to drive the car yet but it starts and runs and the ecu didnt explode when I hooked up the battery so that is a victory for me. :) Tomorrow the plan is to put the wheels on and get the car out of the garage so I can start the paint work.

Reply #11November 26, 2016, 06:31:28 pm

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #11 on: November 26, 2016, 06:31:28 pm »
The car is officially done.....for now. It goes for inspection on wed. I drove it about 2 miles yesterday. 5-speed swap seems good. No issues. Paint turned out nice and I think the most difficult part of this project was cleaning the car inside and out after the previous owner. It was absolutely DISGUSTING! I dont know how they could stand to dive it. It was a lot of work but it looks like a different car on the inside. The interior wasnt damaged it was just filthy and neglected.




Reply #12November 26, 2016, 10:56:53 pm

ORCoaster

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Re: 2002 TDI Wagon 5-speed swap
« Reply #12 on: November 26, 2016, 10:56:53 pm »
Nice looking machine.  And I love that green grass without the fences too.   

I don't know why some people trash a car like that.  Disposable to them I guess or lack of pride in it and maybe themselves?

5 spd in a wagon.  That will do great on a long trip.  Might find when fully loaded uphill it needs to drop to 4th for climbing torque. 
Now Own 1981 Caddy as the NEW DISTRACTION to all that is around me.  Project Away!

Reply #13December 01, 2016, 05:57:22 pm

Millennium Falcon

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Re: 2002 TDI Wagon 5-speed swap
« Reply #13 on: December 01, 2016, 05:57:22 pm »
I just picked the car up..... It passed the enhanced inspection! Its plated and I drove it home! It feels great to have it all come together and actually work. It does not feel good to pay for the inspection and title transfer... PA fees are not fun. This brings my grand total to $3,031.50. And I still have the extra ALH engine and parts car to try to recoup some of that back. I will be keeping the engine but the rest of the car is up for grabs! Thanks again to all for the advice and tips!

 

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