2003 Eurovan MV VR6 24V manual swap notes

[Endopotential]

[paddygarcia]

The emulator will put the trans controller into D, shutting off the reverse lights, but to make them work with the manual you'll need to wire the switch on the gearbox into the PNP relay. See my post here: https://www.thesamba.com/vw/forum/viewtopic.php?t=...p;start=33

[brc76]

Any chance you guys have the part numbers or link to the correct driveshafts for the conversion?

I think I may have an issue with the ones I purchased. The issue is that I have a vibration that is present on accel, driving straight or turning right, but dissappears completely turning left.

I can see some mild play in the drivers side d/s when rotating the wheel.

Pushing the clutch in sometimes makes the vibration stop, but not always.

Before I push the button on replacement of the d/s, I would just like to confirm I have the correct one!

[paddygarcia]

I don't have the part numbers, but axles and CVs for the manual swap are the same as for the 12 valve automatic.

[aereo-van]

Are the 02M (6 speed) and 02J (5 spd) both feasible transmissions for swapping on a 24v EV VR6?
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2003 Eurovan MV

[EuroTec]

[gesoffen]

A few questions for EuroTech, PaddyGarcia or anyone else with knowledge:

1) Reverse light switch: from tracing wire diagrams (and PaddyGarcia's post on his conversion thread), I intend to run the reverse light switch to the area near the PNP Relay (175), remove the existing pins 4 and 5 and insert in the reverse light switch interface between those two wires/pins. This will energize the reverse lights when the gearbox is in reverse gear.

2) Starter interlock: I'd like to wire in a clutch interlock to the starter (e.g. depress clutch to start car). Any ideas on how to work this on the later model Eurovan/T4 (i.e. the 24v VR6)?
I saw Paddygarcia modded the relay which, to my understanding, effectively bypasses any interlocks. I will use this as a back up plan (I have an ACVW that doesn't have any interlocks and thus understand the risks).

3) Cruise control interlock: I have a cruise control pedal switch and intend to wire it into the brake switch interlock for cruise. This should cancel cruise control when either pedal is depressed. However, I don't know if the ECU also wants a clutch signal separate from the brake signal for throttle modulation. Any ideas on this one?

Regards,
Brian

[EuroTec]

RE: #2 & #3

There should be a mount for a 4 pin brake light switch on the clutch lever support. Those 4 pin switches have NC (normally closed) and NO (normally open) pairs. So, you can set one up on that clutch lever that allows two functions; starter interlock and cruise control kick out when the clutch is depressed.

The latter is handy. Nothing like ripping along at 80 mph, push the clutch and hearing the engine scream until you tap the brake!
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If it ain't broke, don't fix it!

[paddygarcia]

I agree with Dean on the clutch switch. Didn't do it on mine as I don't use cruise and didn't have a starter interlock on any of my other cars, but that's not right for everyone.

The reverse switch is pretty straightforward. I found a used Jetta part with connectors and a wire pigtail on eBag for about 10 bucks.

[mk1motorsport]

Question: Is a 5cyl. transmission bolt pattern and the VR6 transmission bolt pattern the same?
I’ve sourced an 93 Eurovan with a 5cyl. Manual in it but didn’t know if the 5cyl. Bellhousing would bolt up to the VR6 engine. I know the VR6 and 4cyl. were different.

Thank you

[EuroTec]

[mk1motorsport]

[gesoffen]

Well, I've completed my swap and can now contribute several nuggets back to the community. First, I gotta give a few shout outs:
1) To those that document their DIYs with detailed steps, photos and videos on this forum (as well as others) - Prost! I had intended on doing something similar but could never remember to bust out the camera/phone or take the time to write detailed notes.
2) To Eurotech for making the transmission emulator - Prost! Usually, with big projects, the first 90% of the work is easy but the last 10% is the hardest and takes the longest. In this case, that last 10% would have been sorting out the electrical gremlins to make the engine ECU happy. Well, Eurotech's little box of genius makes this a 5 minute plug-and-play affair. Not to mention his documentation of the swap here on the samba as well as his general mechanical knowledge of these vans - he is great resource to our community!
3) YogiVW - he sourced the 5 spd manual (02G DYA in this case) and related components (shifter, pedals, mounts, axles, clutch, etc.) from europe for me. Components were well packaged, shipped quickly, and arrived without drama. For those considering a similar project, or looking for Euro spec parts, I highly encourage you to reach out to him.
4) PaddyGarcia - he let me experience his EV Weekender post conversion which helped convince me to take the plunge. Similar to Eurotech, his notes on the swap and mechanical restoration were very helpful.

On to the few nuggets from my swap:
I chose to switch to the manual for two reasons: a) My EV Weekender is the first automatic transmission vehicle I've ever owned in nearly 40 years and ~20 cars worth of driving. I'm not a fan of automatics so the 01P had to go. b) the differential in my van was noisy and weeped from one of the output shaft seals. I tried several cycles of fluid service and replaced the output shaft seals but neither issue was resolved. Failure hadn't yet happened but was inevitable.

I elected to remove the engine/trans as a unit but left the AC circuit complete to avoid the hassle of refrigerant evacuation. While doing the swap, I essentially rebuilt the front suspension (new bushings, bearings, ball joints, etc.) since access with the engine and trans out would never be easier.

While YogiVW supplied the Dual Mass Flywheel, clutch, pressure plate and throwout bearing/slave cylinder as used components with his "kit", I wanted to use new consumables where possible. Unfortunately, the 10 bolt 219mm dual mass flywheel is NLA here or in europe so that left two options:
- Run the used DMF with a Luk 17-052 clutch kit (clutch, pressure place, and throwout bearing/slave cylinder.
- Switch to a SMF and clutch combination from a similar era VW (in this case a MkIV Jetta/Golf with the 12V VR6). This would be the Luk LFW 254 with Luk 17-036.

I had initially decided to go the SMF routeunder the “0 miles on the consumables” philosophy. However, the clutch kit did not come with fasteners for the pressure plate to flywheel. I ordered them but lost patience in the delay and ended up fitting the DMF while waiting for the order to arrive. I did mock up the SMF with some used hardware and it looks like it is a viable option. I’ve kept the SMF and its related clutch components on hand if the DMF fails.

Regardless, neither flywheel comes with hardware. New flywheel to crank fasteners: N90665001 x 10

YogiVW also supplied used axles in the “kit” but similar to the clutch, I wanted to refresh them to a zero mile state. This would have meant rebuilding the CVs, new reluctor rings (YogiVW had thoughtfully included them) rebooting, and cleaning up/painting the axles themselves. However, I found “new” aftermarket (Meyle) axles still available for a reasonable price and went with those: JZW407449GX for both left and right side. These axles are the right side axles for a 12v VR6 van with the 01P auto. Due to the difference in tans size/output shaft offset, the right side auto axle also fits the left side on the manual. The axles that came with the 24V VR6/01P trans are have larger diameter CVs and splines so do not fit the 02G manual trans output shafts.

Other odds and ends:
- Between the flex plate and crank of the auto trans is a washer and spacer. I left both out when fitting the DMF. I don’t think you need them for the SMF option either but I’ve thrown mine into the “just-in-case” parts bin as they are also hard to find/NLA.
- The starter is different for the manual trans. YogiVW set me up with a new starter but it looks like it's the same part number as the 5cyl vans with manual trans.
- I had intended to wire in a clutch interlock for the starter and cruise circuit. However, it appears the 24V ECU in these vans were never coded to for a manual trans option. Limited exploration with VCDS did not show much promise so I went with PaddyGarcia’s PNP relay “short circuit”. Without the interlock, you can start the car in gear without depressing the clutch pedal so you have to be aware, especially if you are used to modern cars. I still have muscle memory learned from my ACVW days when there were no such interlocks. Cruise control still functions as normal but there is no “cancel” when the clutch is depressed. I haven’t seen how the engine ECU reacts to sudden changes in RPM (i.e. depressing the clutch) yet but will investigate for curiousity’s sake at some point.
- MPG is up 20-30%. I’ve only run ~500 miles so far so too early to tell with any certainty but on the first full tank of gas, I saw just under 21mpg under driving conditions that typically yielded 16-17mpg in the auto. With the DYA in 5th, 70mph = ~2450-2500 rpm. This is likely a big help to the MPG but it does put the 24V engine on the soft side of the power band - down shifting to 4th is encouraged for passing or any significant hills.

I'm not sure what I'm going to do with the 01P auto and associated components (shifter, axles, torque converter, Scan Gauge, etc.). Besides the noise/leaky diff, everything worked fine. I may rebuild the diff and then look to sell. In the meantime, I have it sitting in a crate in my garage.....
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1973 VW Superbeetle (1302) w/ RAT 2270 T4
2003 VW Eurovan Weekender w/ 2.8L VR6 AXK, DYA 5 Spd Manual Conversion

[YOGIVW]

Good to see you finished conversion. And I'm glad to se you are happy with our service.
And if any one after full kit I have one in stock + one extra gearbox
Price for full kit is $3600 + shipping. Unfortunately $US dollar is very weak comapring to my currency at the moment
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Pawel
Vw 1303 1979 Black&Beige convertible
VW T4 2001 Caravelle Business 2.8 V6
VW T4 2003 Karmann Colorado 2.5TDI
Westfalia James Cook 2.9TD

[paddygarcia]

Congratulations! Now drive the wheels off it.