2002 VW Jetta automatic to manual transmission swap
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- Опубликовано: 22 май 2015
- This is an overview and timelapse video of one of my recent projects; I swapped a manual transmission into my 2002 Jetta TDI. The automatic transmission was beginning to slip, and this was the best solution I could come up with. It wasn't too bad; I was able to accomplish the swap in one full weekend.
Link to the swap instructions here:
pics.tdiclub.com/data/517/Boer... 
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Excellent work. Way to shout out to boraparts. You made a good choice holding on to that Jetta. You live in a beautiful part of the country; different than here in Arizona!
you should have uploaded the whole thing for people can actually perform the project themselves.
my trans is finally starting to slip, luckily this video taught me a few things about swapping to manual. good job & thank you for the vid!
Nicely done.
I have an '03 Jetta that I am using as a 1.9L ALH engine donor for a '91 Miata. I was planning to sell off the remaining parts individually and didn't even think of selling parts for a complete manual transmission swap kit. I guess I didn't think there was enough people wanting to swap to a manual in the US.
Great video by the way! I enjoyed seeing the time lapse and seeing it come together!
I have the exact same car. I love it, but i'm having the same issues and will be looking to do the same. Good job!
Nice video and great job. I managed to overhaul my 01M valve body before it started slipping and it runs great. About to do a manual conversion on the car anyway for a fun project.
Badgertronix At how many miles ?
Charles Calkins 160,000 give or take. Thing runs great now
Thank You! I got it now!! Works good! Had to change the fuel quantity a bit, but it's all good now! Thanks again!
You hear folks say....oh just toss an engine in or a trans n....haha. That looked like a ton of work and very well done.
awesome! im about to begin this with my mk4. muat be a great feeling once completed and driving smooth
how much did the swap costs?
Beast mode mechanic! I'm jealous of your shop! Beautiful good job on the video, Thank you
Thanks! I'm just a hobbyist, but I really do enjoy taking on bigger automotive projects like this tranny swap. I have a few other engine/tranny/suspension swap videos out there. Most of them Suzuki related...this was my first transaxle swap. But, it came out well! No problems with it after almost 2 years.
I'm self taught too and love it. You did a really great job covering the project, fun to watch.
What did you wire the safety switch to
clutch switch gets wired to relay 53.
Great video, about to do a swap and this video is a huge help. Thank you!
wow.... that was awesome!! I have a low mileage (42k) 2002 TDI Beetle up here in Central Ontario Canada and I plan on doing this when my auto finally dies, as I'm quite attached to my car. I dont have a hoist or anything though so I have a feeling I'll be paying someone to swap the O1M. Although hopefully my auto still has quite a lot of miles left in it.(unfortunately, as I'd love to swap now) Although with these transmissions... you really can never know for sure how long they are going to last! Loved the video though. Fantastic job! Definitely jealous.
PS, now you also have a very valuable set up that many stock manual guys list over. A 5 speed and pricey 11mm injection pump that came stock with the auto compared to the standard 10mm pump that came in the manual cars. Makes the 11mm pump cars a little louder since they have smaller nozzles, but certainly a cool setup now thats for sure!
Michael Shone Thanks! I wasn't aware that the auto cars had a different pump...good to know! I had planned on doing some research on power modifications in the coming weeks. I'm an experienced wrench turner on 12 and 24v cummins engines and also have some experience with 7.3 and 6.0 powerstrokes, and have fully built two older 1.6L VW diesels, but the ALH TDI is a new engine to me.
Chapeau bas Matt. Your Jetta got a new life :)
You make that look so easy !
I've got MK4 Golf 1.6 with 01M that started slipping in 4th gear at operational temperature. Even though the car has 320000Km the engine and everything else feels rock solid. Soon I might be doing a manual swap.
All the Mk4s you see in junkyards were either in bad accidents or the auto transmission failed. The engines will go 500k mi if they are maintained. The 1.9tdi will outlast the appocolypse, the 1.8t is a tank, and the 2.slow is stouter than even the cockroach…. It’s always the trans. If we all (I’m in the middle of a 09a tiptronic to 02j 5 sp manual swap as we speak) just swap them all to manual they will stay on the road for another decade. Cheers VW friends!
Good Job! Great video, I'm gonna have to do this on a 2003 Beetle this helped.
thank god, a car video without edm in it lmao
Like to add the power steering pressure line is different from auto to manual , they make 2 different power steering lines for manual Transmissions one with a/c and one without, the most common is with a/c and it’s cheapest to buy on eBay $100 for a sunsong brand (most aftermarket hoses use this company and put it in their box). Also the brake pedal is hard to get off even if you have the special tool. You can cut the pedal down, the automatic pedal just has a plate welded to it or I would buy a new clip for the pedal on eBay for 6 bucks it saves a bunch of time just to replace the clip and break the old one. If you need the connectors for the Transmission cables eBay has the normal pin style but if you need the socket style ecs tuning is the cheapest at about $45 shipped for 2 of them. The connectors are called “Bowden cable catch”. I have a pick and pull junkyard in my area, I was able to get the clutch pedal assembly, master cylinder, hose, switches, brake pedal, shifter with cables, bolts, Transmission mount for under $45 bucks so I would highly recommend going to a pull it yard. All my stuff was taken from a beetle. I do a lot of work on these cars so I had some of the other stuff laying around and bought a Transmission with 70k miles off a customer for 300. I’d say I’ll have about 600 bucks or less into the swap. I did use a dual mass flywheel and clutch but only because it came with the Transmission and was in 90% good condition but i also am a mechanic by trade and have a lift at home. If your paying someone to do this job or doing it on your back I would get the single mass conversion kit. This is a good video, a lot of other videos aren’t 100% on what you need.
A la gran!!! Very well done. I'm so jealous that I will do just the same with my 01 Jetta. Thanks for sharing
sewerzuk did you have to program the computer at all?
That's a great project.
You couldn't get a sunroof and stick shift together from the factory, and depending on the year power windows.
An additional benefit would be now you have a larger injection pump and injectors than would come with the manual. Originally to overcome the torque converter power draw.
Enjoy your TDI the automatic transmission was your weakest link.
Looking into doing this when I finally get myself a Beetle. Gonna' find a cheap auto, drive it 'til the transmission dies and swap in a manual.
Not sure which engine I'm going to get, but might engine swap whatever's in it too depending on how finances look. If I go through with it, I'm a little torn between doing a VR6 swap, or the 225 hp 1.8T out of a TT quattro. Maybe if I win the lottery I'll have it converted to AWD as well. :P
This might have been the most enjoyable tranny swap video I've ever seen.
My only use for music would be to cover up all the cussing!
Beautiful work !!!
I did the swap on my 02 Passat v6 TDI, the mechanical part was fine but I'm still having issues with the ECU having no response from the TCM, any clue ??
Thanks
Looks like you did a great job! I was just wondering if I could switch my 7 speed automatic, to a 6 speed manual transmission on my 2012 Infiniti G37 x and you know around how much it would cost?
Good Job! But as exacting as you are on generators and other things it was not much of a problem for you. I felt for you on the add-on's though. You never know, as you said but it worked out really nice!
Thank you for ....I have a 2003 JETTA I need to swap out..Where did you purchase????? KIT
great vid, and thanks for the pdf added info as well!
have you already, or planning to do the euro 5th gear swap in your trans?
Would you recommend repairing an automatic on my 2005 MK4 Jetta 2.0 GLS or swapping it out for a manual? According to the vw mechanic the transmission differential broke after I described a mechanical clunking sound at about 30 mph. The car has approx 104k miles on it. I'm looking for the most affordable option but will consider a more expensive one if it means adding life to the car. Appreciate your feedback! And great video!
Good job. Too bad you didn't make a series out of this swap. I hear that some of the swaps many are now doing are 6 Speed manuals. The biggest knock against Tiptronic and DSG's isn't really the transmission design (relative to other makes). Its all a matter of maintenance. Changing oil regularly in the trans is a must or it will burn up. It is true that the frequency of the change of fluid is much shorter than traditional expectations. 50,000 miles is pretty much mandatory. Solenoids get gummed up pretty easy too.
Great vid , Good swap man !
Great vid I am wanting to do this with my 05 golf
I heard that any o2j transmission can be used with any 4 cyl engine VW mk4 from 00-05
hey awesome swap. im going to be doing the same on 03 jetta wagon. did you have to do any mods to the wire harnes or reprogram the computer?
beautiful video man, i just picked up a 99 gold gls 2.0 with 30k miles and my goal its to do the same once the transmission goes out long way to go tho :)
Did you ever swap,?
Nice video, great shop !!
Great video. Note: Do yourself a favor and upgrade the front brakes to the MK4 GTI rotors and calipers. You'll see a huge improvement in braking.
Nice helpful vid! I'm also looking into swapping my automatic transmission to manual for my 2005 lancer . I really don't wanna sell the car but the costs so far is quite pricey. Is there any way of swapping it without costing me a lot.
can i say im all set, if i got a working car (motor and manual transmision) and i want to swap into my automatic transmission car?
what else should i considered?
thank you, goood job!
Looking for some heads up...
I have a 2004 jetta 1.8t automatic, i also have a donor vehicle 2004 jetta 1.8t manual.
So far I understand that everything should fit with no problems, my only concern is the speedometer and the rpm, since I swapping tranny what do we need or what I dont need to have the whole dashboard working?
Great work! Wish I could of lent a hand! love the videos
Great video. VWs last forever!!
on passat b4 i change the transmission from automatic to manuel and the abs and esp fault??
Nice video.
One question.
Can so the swap with automatic module..and wiring?..
Great work bro
good job i have a vw golf 1.6 iv automatic and its doing that samething ..
Nice work man I opened the link for how to wire the sensors but is too complicated for me I just need to make it work the speed sensor and the reverse sensor do you have an other easy way to make those work? 03 jetta tiptronic to a manual 5 speed thanks have a nice day.
Where did you say you got the kit from?
Hey noticed you are from oregon. I am also from oregon and will be doing a manual swap on a mk4 2.0 and was wondering if there was a way I could ask you a few questions about the swap.
Hello
Please can you explain me i want to change the transmission automatic on manuel but my transmission is 1.9Tdi 130cv and the manuel is 1.9Tdi 115cv ,now is same for change or not please .
Yeahhh.. 😂😂 I know that feeling..!! when you start a project and turns out the way you aspect.. 😄
Damn. I need this done to my 02 Jetta. Can't drive a Standard, but the 01M Auto is terrible. Mine just went out, it's being replaced with a VW reman.
great video, I have an identical car to yours (white/leather)... So I also ordered the $1500 shipped 6MT Skota diesel trans from Frans at Dutch Auto. I will be doing the swap in the next couple weeks.
Have you considered doing a stage up for a little extra power and mileage?
Do you have a website?
Hey there what web sit was that kit from going to swap my gti to a manual 6 speed can't find no kit anywherev
I got one Golf GTI 1.8 my transmission is broke can you tell me how much it cost for swap the transmission please
Bro you did that shit so effortless
Thanks very much for sharing your project. Your video was excellent and your explanations were very helpful. I was wondering if you installed the 5spd or 6spd manual transmission?
5 speed. I couldn't locate a 6 speed without a long lead time.
Did you change the ecu??
Awesome video!
Hey i just did the conversion but still using my old starter was told youd have to trip it ,do you know how?
i just swaped today to manual my pasat b5.5 and i think it runs good but is it worth it
I want to do things a little different, I want to save my 2002 tdi autotrans and buy a MK4 manual TDI, can I use my low mileage 2002 tdi in the manual car as a direct bolt in, in the future??
Cool vid!
Sick video!
What was the name of that place you ordered your transmission kit?I want to swap my auto into a 6sp manual, and swap my 2.0L into a 1.8T
Would this be the same for a 2008 va gti and how much did everything cost
sewerzuk do you think this is possible on a 1985 golf?
So is there any difference when bolting a manual to automatic engine. Is the crank compatible for both transmissions.
Matt... awesome video. Working on the swap now. Was wondering what you did with the coolant lines off the top of the automatic transmission cooler. Did you leave the metal coolant lines?
Chuck Taylor good question...it's been long enough ago that I can't remember. I do remember swapping out a housing on the side of the head, but I honestly don't remember the details.
Thanks for the quick reply Matt
I hope my 2012 passat lasts as long as these jettas. I just got it at 56k miles and fingers crossed
could you explain in brief some of the wiring you did for the tcm and ecm. and how you got the car to start with a automatic ecm id really apriecate it!
+Hector Garibay Basically, I just unplugged the TCM for the automatic and let the harness dangle. The car will start/run/drive this way, but cruise control doesn't work and the MIL stays on. The ECU needs to be re-coded for manual transmission (easily done inside of VCDS), and a "clutch disengaged" +12v signal needs to be sent to the ECU. Those are the only real changes; details on the pins used are in the swap guide:
pics.tdiclub.com/data/517/Boertje_Auto_to_6_spd_manual_swap_and_wiring_instructions.pdf
Excellent video. U made it seem like a piece of cake.. just have one question .Do We need to change dashboard cluster pnnel and ECU . Or the same can be reprogrammed via VCDS or other softwares..
Will really appreciate your revert... And keep up good work./,,/
Nishant Luthra I left my instrument cluster in place. The TCU is just unplugged. ECU is programmed with VCDS software to stop looking for the auto trans. Quick and easy to do. The details are in the instructions link I provided in the video description
still no check engine light, damn. i have mine on for emissions, but mine is automatic as well and i cannot find a manual in my area for the life of me!
Hi. I have a couple of questions . I own a 2000 beetle and 2002 jetta . both 1.8t jetta automatic transmission .need to do same as.you but .what about the connection to automatic to manual wires? won't affected the computer.
Excelente video and job
You are very knowledgeable :)
Nice i thought about swapping my 2.0L and auto Tranny out for the 1.8T and 5/6 speed tranny!! I thought about getting my stuff from Ebay.
does this transmission work for a 1.8 turbo engine? i have and Auto that i hate i would love to do this
Where did you get the kit for the manual I have a 2003 Passat 1.8t auto
I have a 2004 GTI 1.8t It used to be Tiptronic Transmission, but a friend of mine swapped a Manual 5 Speed Transmisión, everything worked perfectly after the swap except the Speedometer, did he made a mistake with the wiring harness? RPM And all the needles work except the speedometer.
would this be the same process for a 1.8T on a 2005 GTI?
Wish I woulda caught you 7 yeArs ago to check your coil packs and spark plugs that hill thing was fixed for me after that on my 1.8t
Hi Matt, great video. Soon I will also do an auto to manual swap on my tdi and had a few questions. -What happened with the wire connectors to the auto trans when you swapped it to the manual? Do they go onto the manual trans?-Was disconnecting the auto trans control module the only thing you disconnected from the harness?-Is there a direct connector by the brake pedal wiring to connect the clutch safety switch?-Was there any predrilling involved in getting the clutch pedal with the clutch master cylinder installed?Cant think of any other questions right now but would appreciate any and all other advise or things to look after during the project. Thanks,
Some of those questions are answered in the instructions I have linked in my video description, but I'll try to answer them here: things like the reverse switch, VSS, etc. use the same connectors on the auto and manual transmissions. The ones that don't get used are taped up and left unplugged. The TCM is simply unplugged and removed, the ECU is reprogrammed using the VCDS software to stop looking for communication with the TCM. There is no direct connection for the clutch safety switch; that must be spliced into the harness. Exact locations are described in the instructions. No drilling is required; the clutch pedal assembly and master cylinder bolt right in to existing holes/studs/etc.
@@MattVerley this is an old video but looking to buy a TDI project myself and do this swap. If I don’t bother wiring up the clutch safety switch, will the car still start and run without it?
My aunt has a 2002 New Beetle TDI and shes looking into doing this, thanks for the video! Where in Oregon are you? I'm in Coos Bay! I got pretty excited when I saw you were in the same state, lol
near Seaside. a few hours north of you.
You didnt have to do anything to the ecu? Just run power to the clutch to give it power for the clutch switch?
very well done video by a very fine mechanic. Did you post links for the kit and what the cost was?
There is no real link to the kit; I ordered mine through Frans at Dutch Auto Parts. I contacted him through the TDIclub forum. Total cost was around $1300, IIRC. That included the used and new parts.
Good video!!
Great video, thanks for sharing! Did you have a check Engine light on after the swap for no communication with the trans control module? (P1626 ) I did the same swap and now i have this code.
Peter S I used VCDS to re-code the ecu for manual, so no check engine light.
@@MattVerley is the re-code easy to do?
what was the total cost of the swap new and used parts?
Is it possible to do this without a lift? I need to take the transmission out of my 04 jetta manual and put it in my 06 jetta automatic
the tdi 02j manual trans will fit in a mk4 2.0gasjetta correct?
It works the same on a 1.8T Jetta?
Good for you!
Hey great work i am currently doing a swap on my 1.8t but i need help. How did you manage to recode the ecu from auto to manual? right now i got the manual in and everything drives fine but my speedometer doesnt work and i got an engine light on.
Phillip Dorofy The speedometer should work fine without any changes in the ECU; the connector for the auto and manual speed sensor is exactly the same. It just plugs right into the VSS on the new transmission. The VSS is in a slightly different location; closer to the firewall. As far as the re-coding goes (necessary to clear the CEL and make cruise control work) you need to find somebody with VAG-COM to plug in and re-code it for you. It's quick and easy...just a few minutes. You can usually find somebody close to you by just asking in one of the VW forums, but here is a locator with links to people who have volunteered the use of their VCDS software to those who need it: www.maptive.com/ver3/VCDS_Locator
Got me 2004 gti golf auto !! Wish I could or had the no how to do that to mine 👍
I have a 2011 Jetta 2.5 SE. How much do you think it cost the conversion from automatic to manual in that car?
We're did you buy all the pieces for the swap???
I just want to know how you did a slow pan while the video was speed up... that boggled my mind. Although it's probably super simple and already been asked (but I couldn't find it). Nice work btw
+Defeated Purpose that's funny...I've had at least a dozen requests about that exact topic. It appears to be more interesting than the transmission swap! I built a motorized camera slider out of a 6' drawer slide. I have an overview video here: ruclips.net/video/FFwv6WH9gHs/видео.html
Did you have to recode the ecu from auto to manual after the swap? Or how did you get passed that? Sorry i know this is from 2015.
How did you get dutch auto parts to send you the transmission parts