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    Thread: 5-Speed Swap - MK4 2.0 Auto to Manual

    1. Member VDUB MKIV's Avatar
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      05-21-2010 12:45 PM #1
      Well today I started my 5-Speed swap.

      Dropping Trans...

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      Trans out...

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      Transmission going in...

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      Ran into a issue with the crank shaft. Diameter is a little bit bigger so the flywheel will not be able to bolt on.

      The way to get around this is to get a professional machinist to slightly bore out the flywheel. I'll explain more on how about doing this once I get some more info.

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      My automatic trans is getting swapped into another Jetta with a bad automatic transmission.

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      Will keep you guys posted...
      Last edited by VDUB MKIV; 05-21-2010 at 10:10 PM.

    2. Member elRey's Avatar
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      05-21-2010 12:59 PM #2
      Cool. went thru this myself. What flywheel are... I mean were you going to use? Are you cutting the trans/TCM wiring or swapping a manual harness in? Which ECU? reverse light wiring? Clutch switch wiring? 1.8T or 2.0L 02J tranny? swapping just the clutch pedal or smaller brake pedal also? What are you doing about the cluster?

      Just things I dealt with.

      Keep up the good job!

    3. Member VDUB MKIV's Avatar
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      05-21-2010 01:22 PM #3
      Quote Originally Posted by elRey View Post
      Cool. went thru this myself. What flywheel are... I mean were you going to use? Are you cutting the trans/TCM wiring or swapping a manual harness in? Which ECU? reverse light wiring? Clutch switch wiring? 1.8T or 2.0L 02J tranny? swapping just the clutch pedal or smaller brake pedal also? What are you doing about the cluster?

      Just things I dealt with.

      Keep up the good job!
      I'm using a stock 2.0 Flywheel, it seems the center was a little bit smaller and I'm thinking this is because it's a automatic crank. But I took it to a machine shop and they got it taken care of.

      - I'm just keeping my wiring harness and going to cut it etc...

      - I'm keeping my stock ECU and using VAG-COM to change it over to a Manual

      - Putting a 02J in it from a 2002 Beetle, my car is a 2003 Jetta so it should be fine.

      - About the reverse and Clutch wiring this will be last to figure out.

      - I have the clutch pedal and I'm just going to trim up my brake pedal.

      Is there anything I need to watch out for? I'm doing this swap in 2 days so any advice would really help.

      I also have the shift linkage but I think it was from a 6-Speed, I'm sure it will fit right? If I get the correct bracket that goes to the trans?

      Thanks

    4. Junior Member
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      05-21-2010 01:25 PM #4
      Woah. Heck of a project you got there. Best of luck!
      2006 Audi A3 & 2005 VW Jetta GLI

    5. Member elRey's Avatar
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      05-21-2010 01:28 PM #5
      Quote Originally Posted by VDUB MKIV View Post
      I'm using a stock 2.0 Flywheel, it seems the center was a little bit smaller and I'm thinking this is because it's a automatic crank. But I took it to a machine shop and they got it taken care of.

      - I'm just keeping my wiring harness and going to cut it etc... <- this is what I did

      - I'm keeping my stock ECU and using VAG-COM to change it over to a Manual - not gonna happen, sorry

      - Putting a 02J in it from a 2002 Beetle, my car is a 2003 Jetta so it should be fine. np. but you might not like the ratios

      - About the reverse and Clutch wiring this will be last to figure out.

      - I have the clutch pedal and I'm just going to trim up my brake pedal. - would like to see this when you get around to it

      Is there anything I need to watch out for? I'm doing this swap in 2 days so any advice would really help.

      I also have the shift linkage but I think it was from a 6-Speed, I'm sure it will fit right? If I get the correct bracket that goes to the trans? - the box might work, but the cables and/or ends may not

      Thanks
      another thing to deal with is the shift lock/starter relay and clutch/start block relay (lack of one).

    6. Member VDUB MKIV's Avatar
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      05-21-2010 01:32 PM #6
      Quote Originally Posted by elRey View Post
      another thing to deal with is the shift lock/starter relay and clutch/start block relay (lack of one).
      Ok cool thanks for the heads up, I forgot about that automatic shift lock feature!

    7. Member raymondlee's Avatar
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      05-21-2010 01:52 PM #7
      wow that trans looks beter than my paint!!!lol

    8. Member elRey's Avatar
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      05-21-2010 01:54 PM #8
      Also, check the size of your inner axle flanges to the output flanges on the tranny. Early 2.0L 02Js came with smaller flanges.

    9. Member VDUB MKIV's Avatar
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      05-21-2010 02:33 PM #9
      Quote Originally Posted by elRey View Post
      Also, check the size of your inner axle flanges to the output flanges on the tranny. Early 2.0L 02Js came with smaller flanges.
      Oh ok well it came out of a 02 and mines a 03 so it should be fine, thanks for the heads up.

      By the way the fly-wheel is in and bolted up!

    10. Member elRey's Avatar
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      05-21-2010 02:44 PM #10
      Quote Originally Posted by VDUB MKIV View Post
      Oh ok well it came out of a 02 and mines a 03 so it should be fine, thanks for the heads up.
      2.0L 02J vs 2.0L 01M.... is not the yrs that matter in flange size.

    11. Member VDUB MKIV's Avatar
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      05-21-2010 03:11 PM #11
      Quote Originally Posted by elRey View Post
      2.0L 02J vs 2.0L 01M.... is not the yrs that matter in flange size.
      It's a 02J not a 01M so I should be good.

    12. Member elRey's Avatar
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      05-21-2010 03:42 PM #12
      ummm.... what tranny are you taking out?

    13. Member VDUB MKIV's Avatar
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      05-21-2010 04:48 PM #13
      Quote Originally Posted by elRey View Post
      ummm.... what tranny are you taking out?
      The one that I'm putting in my car.

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      05-21-2010 04:52 PM #14
      Skeptical on whether or not this might work, atleast you're at a shop and not doing this in a garage, but I feel like your going to run into a lot of issues.
      Quote Originally Posted by Braga_Dub View Post
      When the Earths normal shift in plate tectonics causes you to scrape while parked. You are almost low enough.

    15. Member elRey's Avatar
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      05-21-2010 05:02 PM #15
      Quote Originally Posted by elRey View Post
      ummm.... what tranny are you taking out?
      Quote Originally Posted by VDUB MKIV View Post
      The one that I'm putting in my car.
      So, you're taking out your 01M 4spd auto and putting it back in? You shouldn't have a problem then. I thought you were taking out the 01M 4spd auto and putting in a 02J 5spd manual.

    16. Member VDUB MKIV's Avatar
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      05-21-2010 10:00 PM #16
      Quote Originally Posted by e36rjbmw View Post
      Skeptical on whether or not this might work, atleast you're at a shop and not doing this in a garage, but I feel like your going to run into a lot of issues.
      Why wouldn't it work? And yes I am getting this doing by professional VW techs.

      And yeah we are running into a few issues, but let me tell you it's a great learning experience.

    17. Member VDUB MKIV's Avatar
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      05-21-2010 10:01 PM #17
      Quote Originally Posted by elRey View Post
      So, you're taking out your 01M 4spd auto and putting it back in? You shouldn't have a problem then. I thought you were taking out the 01M 4spd auto and putting in a 02J 5spd manual.
      Yes I am taking out my 01M 4spd auto and putting in a 02J.

    18. Junior Member
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      05-21-2010 11:03 PM #18
      what would this cost for a 1.8t? i have the tiptronic or however you say it... i want a manny so badly!

    19. Member VDUB MKIV's Avatar
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      05-21-2010 11:29 PM #19
      Quote Originally Posted by brooksie91 View Post
      what would this cost for a 1.8t? i have the tiptronic or however you say it... i want a manny so badly!
      It will probably run around $2500 to $3500 including parts and labor, not cheap. But you can sell your tiptronic for probably over $900 and all the other parts along with it and maybe get around $1200 for everything so that should really help you out.

    20. Member VDUB MKIV's Avatar
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      05-23-2010 03:56 PM #20
      Ok well here's an update, flywheel, clutch etc.. are on, transmission & axles are all bolted up.

      Got the car started and everything worked fine.

      All that's left is to do some wiring / recoding ECU and to get the shift linkage installed and bolted up.

      Should be driving my car home in a couple of days

    21. Member CerealKiler's Avatar
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      04-10-2012 09:13 PM #21
      I really want to do this... I just had my automatic trans rebuilt and they said it's not possibly. Stupid uneducated jerks... Anyway, what is your experience with this? Do you like it? Any issues? This isn't something an unexperienced person should do right?

      Sorry for waking such an old thread. But I figured it's been a while since you had it done and you would have had the time to really review it.

    22. Semi-n00b
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      07-25-2014 08:08 PM #22
      Hey I had done the same thing in my 05 Gli , my problem is I got the tranny on and got the car driving . The mechanic said I need a manual harness to get the check engine light off. So I bought one and I don't know how to install it please give me shout I need some help with my speedo & reverse

    23. Member mark6kevin's Avatar
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      07-25-2014 08:27 PM #23
      work hard. drink harder.


      instagram: itznj
      my thread.

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