TheSamba.com :: View topic - Automatic 01P to 02G manual swap on 2003 AXK VR6

Sun Feb 13, 2022 8:29 pm

I just finished a transmission swap. Took out with the failed auto and installed an 02G AFL from Thomas at Quality German.

YES, the AFL bolted up to the AXK block with only six bolts.

Sorted the starting and reverse wiring, it runs and drives fine BUT the power is down as if it's in "limp mode". ECU and ABS have codes: "missing signal from TCU" which means that my ECU is "looking" for an auto trans. Without it, it's lost and just defaults to a map that allows driving but at a loss of performance.

ABS light is on and I randomly get cam position codes. I can clear them for a while but they randomly come back, sometimes right away, sometimes after several drive sessions.

Can anyone suggest someone that can flash my ECU to remove the auto trans dependencies?

I'm going to try an ECU from a 2003 Jetta 2.6 manual trans just to see what happens.

Thoughts? Thanks.

Tue Feb 15, 2022 4:46 am

FYI I called Ross-Tech yesterday and they verified that VCDS will not reprogram an ECU.

Tue Feb 15, 2022 6:08 am

Disclaimer - I have explored a manual swap for the later model EVs but not actually done one.

You are largely in undocumented waters as I have not found a source that has completed or shared their steps to a successful MT swap to include delete of TCU input and full ABS/ESP functionality.

There are swap blogs here and on VW Vortex but I have not seen one that documents the steps of TCU delete and ABS/ESP restoration, though ABS/ESP may not be important to some.

I'm interested in this swap too but full functionality is important to me - good luck and please post updates!

Tue Feb 15, 2022 12:10 pm

ANS and ESP are not important to me. My main concern is getting the engine to run and accelerate properly and stop throwing camshaft advance/retard codes.

I think it may be an issue other than just the TCU missing. I'm going to dig in and explore more what might be going on. I also changed my timing chain in the process. I was sure I had it exactly right as I checked it two or three times before I reassembled everything. The car starts and runs and revs okay it just doesn't have full power and the throttle is a bit odd. The first 20% or so motion on the foot pedal doesn't do much then it suddenly accelerates. The difference between half throttle and full throttle seems to provide no additional power. I did get one EPC code that popped up the other day, cleared it out and it hasn't been back since. There may be other issues at Play here. I'll update things here as I move along.

Tue Feb 15, 2022 2:50 pm

From memory in looking into this I don't think the 24V Vr6 was ever mounted to a manual transmission in a T4 so there is no ECU version from another vehicle that can be flashed.

In order to deal with the codes you will need to reverse engineer the CANBUS messages that the ECU is looking for and emulate them. Look to the EV conversion crowd to learn about spoofing CANBUS.

Wed Feb 16, 2022 4:05 am

shirk wrote: From memory in looking into this I don't think the 24V Vr6 was ever mounted to a manual transmission in a T4 so there is no ECU version from another vehicle that can be flashed.

In order to deal with the codes you will need to reverse engineer the CANBUS messages that the ECU is looking for and emulate them. Look to the EV conversion crowd to learn about spoofing CANBUS.

You are correct. No manuals in the 24v version.

I have a thought. I had a former employee (of my now out of business service shop) remove the engine/trans assembly. I put it back in so connecting all of the wiring was tricky as I had to figure out where they all went and how they were routed. I had a couple of things initially connected wrong that I later corrected and maybe, just maybe, I have the cam sensors connected in reverse! That would explain the P0011 & P0012 cam codes. I'm going to check that today.

I'm also going to purchase VCDS Enthusiast package today. Should have bought it ages ago. I've used it in the past at other shops but one of my techs had it so I never purchased it.

Wed Feb 16, 2022 6:25 am

I checked my cam position sensor connections and sure enough, I had them reversed! That took care of the p0011 and p0012 codes. I still get an EPC light and when I clear it it wants to come back because there's still a code in the ECU for a missing signal from the transmission. I suspect it's looking for a speed sensor signal. When I get the VCDS I will try to do a throttle adaptation and see if we can get this solved. Just glad I'm making a little progress.

Wed Feb 16, 2022 1:44 pm

Okay I sorted it out! It turns out all I needed to do was the proper adaptation of the throttle body with my Autel scan tool. Once I did that, everything works fine. Really happy about this. Everything works mechanically it shifts fine it runs great and it's a driver. No ABS but I don't care.

Wed Feb 16, 2022 4:06 pm

0-60 in about 10 seconds now!

Wed Feb 16, 2022 4:41 pm

Nice! I'm still wanting the full ABS/ESP functionality so still on the hunt for resolving that part prior to jumping in to the swap. My '02 EVW is the only autotragic transmission vehicle I've ever owned - while the van it self shines in so many other areas, the fact that its an auto is a real let down for me.

Wed Feb 16, 2022 6:26 pm

Euro Auto wrote: Okay I sorted it out! It turns out all I needed to do was the proper adaptation of the throttle body with my Autel scan tool. Once I did that, everything works fine. Really happy about this. Everything works mechanically it shifts fine it runs great and it's a driver. No ABS but I don't care.

Good job on that swap and conversion! Do you think the same is possible on a '99 EVC with a 24v6? I am getting a knock in my auto tran at 170k and am looking into the inevitable options. No codes showed up when the shop plugged it in, so the EVC is being used minimal until they can open it all the way up.

Wed Feb 16, 2022 7:26 pm

generic_ork wrote: Euro Auto wrote: Okay I sorted it out! It turns out all I needed to do was the proper adaptation of the throttle body with my Autel scan tool. Once I did that, everything works fine. Really happy about this. Everything works mechanically it shifts fine it runs great and it's a driver. No ABS but I don't care.

Good job on that swap and conversion! Do you think the same is possible on a '99 EVC with a 24v6? I am getting a knock in my auto tran at 170k and am looking into the inevitable options. No codes showed up when the shop plugged it in, so the EVC is being used minimal until they can open it all the way up.

I don't see why not, but you'll loose ABS and stability control.

Thu Feb 17, 2022 6:39 am

With that in mind Ross Tech could have done the adaption, right?

Thu Feb 17, 2022 7:35 am

gesoffen wrote: Nice! I'm still wanting the full ABS/ESP functionality so still on the hunt for resolving that part prior to jumping in to the swap. My '02 EVW is the only autotragic transmission vehicle I've ever owned - while the van it self shines in so many other areas, the fact that its an auto is a real let down for me.

to save you some time I checked different ECU's out of Golf 4 24V with MT, also VW Sharan VR6 24V 204PS with MT also no luck. Even replaced ESP brain with the one from 2.5tdi 150ps manual transision still nothing.
And if any one is interested I have full AFL set to do the transmission swap over here in Europe but I have no idea how to post it to USA. Price $3500

Thu Feb 17, 2022 10:58 am

subdewd wrote: With that in mind Ross Tech could have done the adaption, right?

Yes, and I should have my vcds package in the mail this coming week.

Thu Feb 17, 2022 11:27 am

More good news this morning. I was too quick to remove the TCM from the vehicle. I actually cut some of the wires going to the plug. This morning I looked over the wiring diagram and reconnected the TCU. ABS & stability control lights are out. Tested ABS out on the road and it works!

I still have a check engine light and a sporadic throttle pedal implausible signal but I'll work that out later. The throttle is still working fine. Taking a road trip with it this weekend. Wish me luck!

Thu Feb 17, 2022 11:54 am

Good luck with the drive!

Interested in knowing more about the TCU - did you reinstall the TCU itself? Did you also need to leave the transmission harness in place? Or is the TCU just completing some of the ABS/TC related circuits which come into the module?

Thu Feb 17, 2022 4:03 pm

bikes! wrote: Good luck with the drive!

Interested in knowing more about the TCU - did you reinstall the TCU itself? Did you also need to leave the transmission harness in place? Or is the TCU just completing some of the ABS/TC related circuits which come into the module?

TCU is connected to the vehicle harness under the dash but everything that connected to the transmission is removed.

Sun Feb 20, 2022 7:13 pm

Well my auto to Manuel swap was done years ago but has never run right since.. It always has run rich, gets horrible gas mileage, and foules the plugs every few miles. We changed the computer, checked all the sencers, still same problem.. But mine is a older model van 93 w a Aaf inline , 108 hp. 5 cyl. It has driven at least 3 owners to sell. It and I just may be next. I'll try your advise next. Thanks Bill

Thu Mar 03, 2022 6:54 am

I purchased a spare ECU on eBay with the immobilizer disabled because I don't have a smart key for this van.. I tried swapping it out today just to see if there was any difference and much to my delight, my cruise control works now. This explains why I couldn't find a cruise control module in the right side of the dash on this 2003 Eurovan. It's built into the ecu. I still need to add a switch to the clutch pedal that will turn it off. If I use a standard 2003 Eurovan brake switch, it has four terminals. Two are normally closed, two are normally open and they reverse positions when pressing the pedal. So if I use the one that's normally open and connect that to my starter relay I have a lock out so that you have to push the clutch to start the vehicle. Then use the normally closed switch and wire that in with my existing brake switch for Cruise control, when I push the clutch it will disengage the cruise control.