sanchius

<i><font color=blue>Originally Posted by sanchius:
You could put a manual transmission in from a 90CS FWD and have an awesome car....
I did and I love it. <b>http://forums.quattroworld.com/v8/msgs/11261.phtml</b>

CRAZY_RUSSIAN
hey sanchius, your cab was OBD1? do you know what to do with OBD2 cars regarding the computer/shifter? i have a friend that i might be doing a conversion to a manual, but i cant find information regarding OBD2 cabs :-( any input would be appreciated </i></font>

Mine was OBD1. I put a craigslist ad up looking for the parallel manual 90CS FWD model and someone gave me one (the black one) for free, then I just put them up on stands next to each other in the garage and swapped everything over. I wouldn't do it any other way. The sedan computer tested out fine in the cabrio. The big pains are cutting the metal spacer off the back of the crankshaft and fabbing up the new exhaust routes near the trans. The red $80 Harbor Freight engine support makes things much easier/safer, highly recommended. I still get a check engine lite and one of these days I'll buy a vag-com and remove it.

Unfortunately I don't know anything about OBD2. Are there OBD2 sedans that you could source from? Let me know if your friend is successful with his conversion.

Below are my conversion links

<img src="http://farm6.static.flickr.com/5228/5623789577_c27ed4db95_z.jpg">

manual

https://www.audiworld.com/forums/sho...php?p=18175274
https://www.audiworld.com/forums/sho...php?p=18595786
https://www.audiworld.com/forums/sho...74&postcount=2
http://www.motorgeek.com/viewtopic.p...manual#p468236
http://motorgeek.com/viewtopic.php?f=6&t=9349
http://www.motorgeek.com/viewtopic.p...manual#p544439
http://www.motorgeek.com/viewforum.php?f=6
https://www.audiworld.com/forums/sho...php?p=18172895
http://www.gowestyautoparts.com/1994...t/Front-Drive/
https://www.audiworld.com/forums/sho...smission+fluid
http://www.bimmernut.com/forum/5-ser...plastic-2.html
https://www.audiworld.com/forums/sho...php?p=18172659
http://forums.quattroworld.com/9080/msgs/29399.phtml
https://wiki.bentleypublishers.com/d...faqs/FAQs+Home
http://forums.quattroworld.com/9080/msgs/26485.phtml
https://forums.audiworld.com/9080/msgs/8154.phtml
https://forums.audiworld.com/12v/msgs/69551.phtml
http://forums.quattroworld.com/9080/threads/3655.phtml
https://www.audiworld.com/forums/sho....php?t=2802522

<img src="http://farm8.staticflickr.com/7236/7109342247_2f90193b51_z_d.jpg">

grillage

You are awesome. Now all I need is a parts car!

sanchius

Here is the Cragslist ad and some info on how you have to remove some metal from the back of the crankshaft.
--
Below is the craigslist ad I ran for the parts car. It took a while, but eventually someone gave me a parts car that they were done with that had everything I needed. It was very nice to just have them side-by-side and move stuff at my own pace. I then stripped the parts car of a lot of stuff: fasteners nuts/bolts, wiring harness, ecu, window mechs, etc (there are some great aluminum bars in the door frames as crash protection) for my parts bin, then gave it to someone who wanted it for the engine.

Wanted: Audi 90 Manual FWD (not quattro) parts car - $200 (mylocation)

Looking for an Audi 90 parts car to fix my wife's car.

Must be Front Wheel Drive (not quattro) and have a good Manual (not automatic) transmission.

$200. Will haul away.

--- Removing the rear flange

Automatics have a larger flange added to the rear of the crankshaft that must be removed. I used a carbide cutting wheel to make lots of cuts to remove the extra metal. The pic below shows the 1st two of many cuts. This is one of these "there's no going back from here points", so have courage. It takes awhile, but it is doable. Air tools help.

<img src="http://farm9.staticflickr.com/8489/8229968068_42925926f7_b.jpg">

Grinding/cutting almost finished, peeling away the last bit of metal from the face. I think I had to bore out the center a bit too to fit the pilot bearing for the clutch

<img src="http://farm9.staticflickr.com/8340/8229968124_494e66f10b_b.jpg">

imncrxtc

Will any other 5 speed from a FWD audi or VW work as well in the B4 Cabrio?

grillage

Thanks again, I have my version of that Craigslist ad running in Cincinnati, Louisville, Indianapolis, Columbus and Cleveland. We'll see if it works.

There are also two pull and pay junkyards here in Cincinnati and they have these cars from time to time.

So on a crankshaft....


You want to take off the end?

Like this?



What holds it in there? It seems like one piece.

And yes, that's what happens to a crankshaft when you run an engine with no oil.

sanchius

<font color=blue><i>Will any other 5 speed from a FWD audi or VW work as well in the B4 Cabrio? </i></font>

I was starting to research manual 100's when the black 90 showed up, so I think so, but I don't know for sure. You also have to convert the pedal box & shifting mechanism. Again, maybe these match, but I don't know.

<font color=blue><i>I have my version of that Craigslist ad running in Cincinnati, Louisville, Indianapolis, Columbus and Cleveland. We'll see if it works.There are also two pull and pay junkyards here in Cincinnati and they have these cars from time to time.</i></font>

Good luck, let us know how it goes....

<i><font color=blue>So on a crankshaft.... You want to take off the end? What holds it in there? It seems like one piece.</i></font>

Yes, take off the end. They look/feel like one, but they are definitely two pieces. What I believe they do is heat the end of the crankshaft (by spinning it in a strong electric field), which expands it, then they stick that flange in there. When the crank cools and contracts, the flange is held very tightly in there. I had a EE friend see this process at work in one of the US auto factories and said it was amazing to watch.

As you can see in my last pic, once I had the flange ground down to almost nothing, I could peel the very last bit away from the crank face and you can see where the top-hat portion of the flange is still in the crank. That pic was 99.5% done. I didn't remove the top-hat portion.

That's the benefit of having the two cars in the air side-by-side. Once you remove the donor trans, you'll see exactly what you need to do by looking at the end of the donor's crankshaft.

<i><font color=blue>And yes, that's what happens to a crankshaft when you run an engine with no oil.</i></font>

Ouch, sorry to see that....

grillage

As to the interchangeability of 012 transmissions, I've been working on that one too. The A4 and Passat used the 012 until 2000 or so and it would be nice to use a newer than 1995 transmission for this.
The gearing is different on the 2.8l engined cars than the 1.8T's so that's one thing to look out for.

What I'm interested in is the mounting of a new trans into the old car.

I'll let you know what I find.

CRAZY_RUSSIAN

thats one interesting looking rear main seal... i remember removing that crank insert, total PITA! head to drill and dremel it out.
here is a fear ration thread on MG http://www.motorgeek.com/viewtopic.php?f=15&t=8293

grillage

Here's an update....

I am about done with the collecting and removal. Soon comes the reassembly! Just got the actual transmission out today.

Pics....

Lord-Of-The-Rings

Maaan... I wish it could be possible to do the same swap on my 98' Cabriolet...