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TheOneTrueQuux
Samba Member
Joined: May 26, 2021
Posts: 360
Location: Winona, MN
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 Posted: Wed Sep 21, 2022 6:39 am Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| EuroTec wrote: |
| Abscate wrote: |
You could compact that with a bank of 90 ohm resistors, 0.5 wattpower rating would be well overrated.
Bad beer rots our young guts but vodka goes well get some now. |
I tried large high watt power resistors, aluminum housing to dissipate heat. Some stay powered all the time. They get VERY (like 350F +) HOT!!!
So, relays. Built to stay on for long periods of time and they get slightly warm. |
So, relay coils are not strictly resistive. They have inductance, which changes when they pull in, and they are fine gauge wire, which functionally means once the coil pulls in, the actual load is less than a static measurement of the coil resistance would lead you to believe. Try measuring the current through an activated relay, chances are you'll find the resistor you need to match that current is more like 100-200 ohms, and a 2-5W power resistor would do the job. |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Wed Sep 21, 2022 3:39 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| TheOneTrueQuux wrote: |
So, relay coils are not strictly resistive. They have inductance, which changes when they pull in, and they are fine gauge wire, which functionally means once the coil pulls in, the actual load is less than a static measurement of the coil resistance would lead you to believe. Try measuring the current through an activated relay, chances are you'll find the resistor you need to match that current is more like 100-200 ohms, and a 2-5W power resistor would do the job. |
May have to check that out. My approach was to simply duplicate what was in the transmission. A solenoid inductive coil that measured 77 ohms. The relays at 88 ohms work ok to do just that, for now. 
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If it ain't broke, don't fix it! |
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richjc
Samba Member
Joined: June 10, 2021
Posts: 2
Location: Santa Cruz CA
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| Posted: Fri Sep 23, 2022 11:33 am Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| Any chance you are interested in making and selling these? We would buy one! Been failing to figure out this problem for a year now. |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Fri Sep 23, 2022 3:16 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| richjc wrote: |
| Any chance you are interested in making and selling these? We would buy one! Been failing to figure out this problem for a year now. |
Yes! Working on a "plug and play" box.
Ideally, you would just plug it into the transmission harness in the place of the transmission itself. One plug each for, solenoids, trans fluid temp sensor, vehicle speed sensor, trans speed sensor and multi-function switch. Five total. Once installed clear all codes with VAG tool. Done. No more CEL for trans issues.
The trick is finding a blank female mate to the transmission solenoid connector that plugs into the top part of the pan with a 11 pin round connector. If I can find something like that, I can put it all in one box. Otherwise, it will be on the installer to cut and splice the wires into the relay pack.
The other connectors I have handled.
Onward....
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Sat Sep 24, 2022 12:24 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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I found a solution to the trans connector and I have ordered all the parts I need to turn this into a plug and play kit! 
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If it ain't broke, don't fix it! |
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richjc
Samba Member
Joined: June 10, 2021
Posts: 2
Location: Santa Cruz CA
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| Posted: Sun Sep 25, 2022 2:28 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| Amazing! We would love to buy one. I’ll PM you. |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Sun Oct 02, 2022 1:48 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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I designed and 3D printed and enclosure then assembled the first prototype of the Transmission Emulator. I'll install it on my van for final testing and I should have it available as a kit within a couple weeks. 
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obieoberstar
Samba Member
Joined: March 07, 2002
Posts: 1126
Location: Tucson
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| Posted: Thu Oct 06, 2022 9:11 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| that is some great work right there. Bravo!! It's all about Science!! |
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YOGIVW
Samba Member
Joined: February 04, 2005
Posts: 263
Location: Olsztyn/POLAND
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| Posted: Tue Oct 11, 2022 5:46 am Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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I'd be very interested in buing a kit. Please keep us updated
Thanks
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Pawel
Vw 1303 1979 Black&Beige convertible
VW T4 2001 Caravelle Business 2.8 V6
Westfalia James Cook 2.9TD |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Tue Oct 11, 2022 7:11 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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My prototype transmission emulator is installed and doing well so far.
As it turns out, as you can see the black and brown plugs can go on either connector. I discovered that they don't need a resistor after all. Each connector has two wires and they simply get connected to each other Plugging them in does just that with a jumper wire instead of a resistor.
Two days of driving with no codes, and I don't expect any. Very pleased!
I'll be ordering up some parts and building kits to sell soon. When they're ready to I'll post a link with info on buying one.
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Unit01
Samba Member
Joined: March 29, 2013
Posts: 9
Location: Las Vegas
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| Posted: Thu Oct 27, 2022 7:06 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| Good good that thing is beautiful! Does your supplier still have manual transmissions in stock? |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Fri Oct 28, 2022 8:22 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| Unit01 wrote: |
| Good good that thing is beautiful! Does your supplier still have manual transmissions in stock? |
Call Thomas at Quality German Parts and get on the waiting list.
http://www.qualitygermanautoparts.com
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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obnoxiousblue
Samba Member
Joined: February 21, 2007
Posts: 2935
Location: East Northport, NY
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| Posted: Sun Dec 25, 2022 4:40 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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When you bought the transmission, where did you source the pedal assembly and all the other required parts to install and operate it?
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1964 Beetle
2001 Eurovan Camper |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Sun Dec 25, 2022 8:23 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| obnoxiousblue wrote: |
| When you bought the transmission, where did you source the pedal assembly and all the other required parts to install and operate it? |
I got it all from Quality German Auto Parts in CA. Ran about $5K
This is what I got in the "kit" he put together for me.
Transmission
Used clutch and flywheel which I installed
Used slave cylinder (I installed a new one just because)
Pedal assembly with clutch master cylinder and hydraulic line
Shift lever and linkage
Right side stub axle and mount
Left and right axle assemblies
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paddygarcia
Samba Member
Joined: January 01, 2020
Posts: 89
Location: VA
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| Posted: Sat Feb 11, 2023 5:40 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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OMG Thank you. I'm in the middle of this swap after a 2 year wait and have never been so happy that a project got delayed.
Have you tried larger value resistors in place of the relays? A 1k resistor would cut the amount of power being dissipated 10x (so a 1/2W resistor would work) but may still move enough current to make the TCU happy. |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Sun Feb 12, 2023 6:25 am Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| paddygarcia wrote: |
OMG Thank you. I'm in the middle of this swap after a 2 year wait and have never been so happy that a project got delayed.
Have you tried larger value resistors in place of the relays? A 1k resistor would cut the amount of power being dissipated 10x (so a 1/2W resistor would work) but may still move enough current to make the TCU happy. |
They get waaaaay too hot! Tried several power resistors with heat sinks even. Hot hot hot!
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paddygarcia
Samba Member
Joined: January 01, 2020
Posts: 89
Location: VA
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| Posted: Sun Feb 12, 2023 8:29 am Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| Sorry, I should have been more clear. Have you tried resistors with a higher resistance? so 1k instead of 100 ohm. Power dissipation in a resistor is v^2/r, so for the same voltage the 1k will only need to dissipate 1/10 the heat of the 100 ohm. |
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EuroTec
Samba Member
Joined: August 24, 2020
Posts: 381
Location: Asheville, North Carolina
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| Posted: Sun Feb 12, 2023 9:11 pm Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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Too high an ohm value and it throws a code. Relays are about 80 ohm. Higher seems to not work.
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paddygarcia
Samba Member
Joined: January 01, 2020
Posts: 89
Location: VA
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| Posted: Mon Feb 13, 2023 7:35 am Post subject: Re: 2003 Eurovan MV VR6 24V manual swap notes |
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| Outstanding work, thanks. |
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