![]() Since there are all of these differences, we're not going to use the transmission, transmission computer, axles, Starter, chunks of the wiring harness, park neutral relay, and probably a bunch of other stuff that was left out just because we're a bit lazy, or didn't take that photo. not there (Duh!) Starter Wiring Harness (Duh!) Park Neutral Relay Notable DIfferences The automatic has a different: Coolant pipe Power steering line Injection Pump Axles Transmission Computer (the manual doesn't have any wires, other than the speed sensor and the reverse switch) Transmission (Duh!) Shift Linkage (Duh!) Clutch Pedal. It's for the budget conscious, or for the green, or for those who want a little more power. This one is specifically from a 2001 Beetle TDI ith occasional shots from a 2003 Jetta TDI. ![]() Who is this for? This instructable is for owners of any Mk4 VW Golf/Jetta/Beetle. ![]() This is my first instructable, Thanks to everyone who voted for me in the Epilog Challenge! I don't think I'm going to win, but hey it's not a bad try! and you want to save some money, and get better economy to boot. 5) Your automatic transmission just died. 3) The automatic TDI only gets about 35 MPG real world, where the manual is capable of delivering a prius challenging 50 MPG. and at $4500 used, it's expensive junk 2) the 02j 5 speed is not junk, and at $600-$1000 used, you can save a lot of money converting. why do you want to swap? 1) the 01m automatic transmission is junk. Slide the bolts from the 5th gear cover side through the mount, into the case and out the other side, if you have the cable tab slip it onto the bolts and then add the provided nuts.Note this is for the TDI only, the 1.8T and VR6 are similar, but wiring, and programming are almost 100% different. If you are running a cable clutch remove the reverse switch and install the provided delete plug, also grab the cable clutch mounting tab out of the hardware bag. great! Now the bolt slides in no problem,Ġ2A CASES, you will now install the shim in-between the upper mount and the trans case to take up the 1.5mm difference in width between the 2 cases.Ġ2j tower (can be used on either 02a or 02j case), if you are running a hydraulic clutch you can keep your reverse switch, skip to tightening down the upper trans mount bolts. ![]() Ok so we’ve drilled the hole and haven’t broken our wrist. You are drilling threaded aluminum, so a bit of speed and very light pressure will help the bit from hanging on you.ĭO NOT try to run this bolt into an 02j case without drilling it out first, you will crack your case and probably wreck it. The 02j case however is threaded, we need to drill them out with a 25/64 bit, you can use a 3/8 and ream it or file it, but 25/64 will be the cleanest/easiest. If you have an 02a case you will find that these holes are not threaded, so no modification is necessary. Now start the tunnel nuts onto the threads of the bolts and run them down tight against the shim and bracket, then install the lock nut after, tighten it down against the tunnel nut. Now slide the mount bracket and the half moon shim on until they are flush to the case of the transmission, once they are onto the bolts, you can thread the bolts all the way into the case, Now Remove the case bolts you see above, and replace them with the 3 bolts provided in your hardware kit, thread them until they are just starting to poke out the other side of the case, Next we remove the speed sensor, you will see that there is a 24mm nut under the plug of the sensor, you can remove just the top section of the speed sensor, this is what you want to do if you plan to use your mk1/2 cluster and one of our speedometer cables. ![]() Remove the aluminum trans mount bracket if you haven’t already and the steel support bar that connects it to the case. Here we start with a fresh mk4 TDI transmission, Code 02j, case is an EGR, The 02a installation is very similar except the shift tower, you also don’t have to drill out any case holes. I am going to cover the install of the MK1 02j transmission mounts onto the transmission before you bolt it into the car. ![]()
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