Iglaaq, the 2002 MV Weekender

[vwwestyman]

Started following this thread, as I'm starting to become nervous that the auto trans in my 2003 Eurovan is getting tired. Should it die, I think I would like to add a pedal.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[paddygarcia]

Thanks, gesoffen. I'm out in western Loudoun.

Dave - if you can find the parts and do your own labor it's not much worse than an auto trans replacement. "Much".

[gesoffen]

I'm in the same boat as VWWestyman - mine has a very noisy diff, likely due to the "lifetime" diff fluid turning to goo at some point. When it goes, I'm going the 3 pedal route, primarily to get my garage back to all 3-pedal rides (also, because I hate A/T period).

You said you sourced the MT package from Rob/VWjunkie - any contact info? I'm not familiar with them.

[paddygarcia]

I'm not sure of Rob's status just now, apparently he's had some family issues.

Several folks have supplied parts, check the board here.

If you want to roll your own and buy parts from Europe, most of the parts are shared with the TDIs also equipped with the 02G: shifter, clutch pedal/plumbing, and I think axles. The starter is different than auto, but I don't know what else has it.

The gearbox and the axle bracket are definitely unique to the VR6.

[paddygarcia]

Forgot to mention about pedals - you only need the actual clutch and brake pedals and their mountings, not the whole cluster. The automatic cars have all the bracketry needed, including for the clutch hydraulics.

With the stub axle bracket sorted I got the passenger side axle installed and the car down off the jackstands. Waiting now for the shift rod and shifter bracket that are inbound from Europe, should arrive in the next week or so.

I couldn't convince the PNP relay to fire the starter with pin 9 grounded, spent time today with a meter and a bunch of jumpers and failed to figure out why. So I modified the relay itself: the black wire runs from the ground side of the relay coil and bypasses the electronics. Marked it so that future me knows it shouldn't be replaced with a stock PNP relay. Starter turns nicely but will have to wait until the radiator is back in to fire it up.

[vwwestyman]

That is a very clever mod!

So far van is driving fine, but the transmission has just started throwing a code for the torque converter lockup clutch, so I'm afraid I may be closer than I think with all this.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[gesoffen]

[vwwestyman]

[paddygarcia]

Lots still to do, but nice to see it out in the rain. Under its own power, even.

[paddygarcia]

I had just left the ignition interlock cable lying free under the shifter boot, but occasionally it must have moved a bit and the key would be hard to get out. Popping the cable off the lock itself keep this from happening.

[paddygarcia]

With about 60 miles and a state inspection on the car I'm about ready to call it shaken down, and overall I share the impressions of Dean and others: this is a very nice upgrade. Not easy or cheap, though.

To be fair, I also freshened up the motor with new chains, a rebuilt head and cleaned injectors, so it runs on all 6 cylinders now, and with the manual it's quite perky. Haven't got enough miles to see if it improves fuel economy, but at about 2100 rpm @ 60mph it might well.

Next up: typical Eurovan things. Visit the local AC shop replace the compressor and recharge, get some quotes to fix up some dents, repair the sliding door inside panel clips, and start replacing the peeling black wrap at window level.

[VanGeek]

You've made a lot of progress! I'll bet you see a fuel economy improvement on highway cruising since 2K at 60MPH suggests a taller gear.
As long as it's not laboring...

I will follow your vinyl window trim replacement process.
I need to do the same. I'm thinking it may involve more window disassembly/removal than I want since the vinyl tucks way under it.

[paddygarcia]

It's definitely not laboring with 2 in the van. Loaded you'd be shifting more.

Vinyl under rubber seals doesn't look too hard on youtube

https://www.youtube.com/watch?v=Kk9Z_llmpK8

[paddygarcia]

Coming up on 500 miles. The CEL reminded me that I needed to do a throttle body adaptation (easy) and an emissions system leak (still working on that).

My search for the correct stub axle seems to be complete, assuming what comes from ebay is what was pictured. I was a little confused at first because the part was listed as coming from a Rialta. Which of course was automatic.

Studying the parts catalog and the t4-wiki I now understand both the stub axle business and the uncertainty of whether automatic trans axles will work with a manual conversion. The 12 valve automatics (DNF, EQE, EQH, others) used the same 02G409905A bracket that the manual uses. They also use the 108mm CV joints and axles.

The 24 valve vans got (only) the EQJ automatic, and also the bigger (120mm?) CV joints. Makes sense, more HP so beefier parts. I think the EQJ must use a larger final drive gear which would move the center out and thus require a different stub axle location.

There are only two part numbers for axles - EQJ and everything else. So I think it's safe to say that a manual conversion of a 12V automatic can use the automatic axles and bracket. Conversion of a 24V automatic will require changing axles and brackets, which can be sourced from a 12V automatic van.

[paddygarcia]

02G409905A bracket arrived and replaced my hacked B bracket.

Now the only non-VW part in the van is Dean's little black box that convinces the TCU that the missing automatic trans is happily living on a farm with all the other 01P transaxles.

HOWEVER my shakedown cruises succeeded in shaking one thing loose - the after-run coolant pump bracket has disappeared. Anyone have one for sale?

[paddygarcia]

Just over 1000 miles. Missed out on a fuel economy check be accidentally hitting the odo reset, but will fill up this week.

EDIT: 21mpg in mixed 30% local 70% 65mph+ highway.

Still have the occasional evap leak, will start with the gas cap and then buy a smoke tester.

It was 23F/-5C here this morning. The engine started right up, the trans took a few miles to warm up and shift OK. I used Pennzoil Syncromesh fluid based on recommendations for VW car gearboxes. It works pretty nicely when warm, but if I drove a lot in a properly cold climate I'd look for another gear lube.

The manual makes for a wonderful drive but does demand finesse for a smooth ride. The clutch engagement is short and fairly sharp, and the the revs hang when you let go of the gas pedal, so you have to balance an early let-off of the gas with just the right clutch action.

Best I can tell the rev hang is there for emissions and there's no way to adjust it from VCDS but I'll keep looking.

[vwwestyman]

I wonder if that rev hang is due to the ECU thinking there is an auto transmission still?
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[paddygarcia]

Very likely!

[paddygarcia]

1500 happy miles. The engine refresh was definitely worthwhile, it starts right up at 15F/-10C and is a really nice runner. As mentioned, the trans is pretty stiff at those temps but loosens up in a few miles - just have to treat it nicely. Then again, one should treat any 02G box well since they're not making any more of them.

We've had about 6" of snow on the ground for the last week or so. The Yokohama Geolander tires are pretty good in it and with a 100 load rating they're just in bounds for the EV, especially since we never drive it heavily loaded. The ESP traction/stability control is also pretty good - thanks again to Dean for the emulator that makes it possible.

[gesoffen]

Hi PG,

From doing lots of research, I'm guessing your rev hang issue is due to not having a clutch switch and updating the ECU measuring blocks to do something with a clutch switch. Similar era VWs (e.g. Jetta/Golfs) utilized the clutch switch as input to the ECU to partially close the throttle during shifts to avoid rev flair/hard clutch engagement.

From talking to you, I recall that you got an 02G AFL box from CdnVWjunkie. Do you remember what clutch/pressure plate/flywheel combo you are using?