Pre-Facelift S8 Manual Conversion?

I own a pre-facelift S8 with a gearbox now stuck in limp home mode,
and unless it's something small like F125 switch, it's looking fairly likely it's
time for a change - the car has 146k on it, 36k of which were mine, so
she's well in the danger zone.

I was wondering what is required to carry out the manual conversion?

My car has the 32v AHC engine, the only conversions I've read about are
in the states using 01E DSY Audi B5 S4/RS4 gearboxes, and on facelift
40v cars, so I know that it may not be indicative of what's to be done on
a pre-facelift.

As far as I know the manual in the Euro S8's was a 01E DGV gearbox,
are there any other cars that had this box, maybe TDIs?

I assume that a different driveshaft would be needed, would the stock
S8 manual driveshaft be available form Audi?

Pedal box, clutch cylinder, linkages would be necessary, would the same
half shafts be ok?

Does anyone have a parts list of what is necessary to carry out this conversion?

[Singh]

Tozo on quattroworld has just done a few manual D2 conversions but he is in the States. It's doable might be worth doing a search on there but please keep us updated on what you find/do. Also pics of your car are a must

[PsYcHe]

I assume it's a right-hand drive car... The work is a bit more involved as there is a lump where the starter motor recesses and this may foul the clutch pedal. I'd be surprised if it wasn't a good bit more to do that getting a recon (or new) gearbox fitted.

Ah yes, pics!



She is indeed right hand drive, so that would be a factor!
This is an older pic, the wheels are standard colour, at the moment they
are anthracite/black (got a second set of alloys this colour), I can't really
make up my mind which I actually prefer....
She's a 1999, which is quite late for a pre-facelift, and is fairly loaded with goodies!

I saw Tozo's posts, mostly on QuattroWorld (do you really have to click into
every single post or am I doing something stupid??), but his conversions
seem to concern later engines, and he's using an S4 gearbox, as he may
not be able to get the normal gearbox in the USA, I don't know all the ins and
outs of it.

I was thinking of dropping him an email but said I'd post on here first in case
anyone has some info?

What kind of price to 5 speed S8 auto boxes run at refurbed?
I'd be hesitant to buy a second hand box that already has 100k+
considering the issues they seem to have, this was the main
reason I was thinking about the manual....

[Conan_the_Librarian]

Welcome to the forum. The manual conversion of a RHD is a bit of a holy grail on here. It's something on my 'to do before i die list'. My research shows that a manual box from Europe with peddle set modifed from another VAG vechile is the way to go. Propshaft also required.

Otherwise its a full fabricated afair with an S2 or S6 manual and custom propshaft and pedal set.

If you do it please keep us updated; and of course you must come to one of the A8oc events so we can see it!

[notorious]

I thought RHD A8 D2s have too tight footwell for 3rd pedal. LHD cars have more space in the footwell because there's no electric box from right.

On top of that, if you have quattro then your new gearbox should "match" your final drive. If they "don't match", then front wheels and rear wheels will rotate at different speeds.

I would shell out 600 - 1300 pounds for gearbox rebuild. Gearboxes are repairable and will work like new if repaired properly-- I see no problem with that. My own opinion...

[Conan_the_Librarian]

Originally Posted by notorious

I thought RHD A8 D2s have too tight footwell for 3rd pedal. LHD cars have more space in the footwell because there's no electric box from right.

That is the case. So a standard foot peddle set from a LHD would foul on the starter motor bulge. A modified pedel set from an A6 however................

[jayzee]

Being an aluminium car, does the art of aluminium welding to the body/chassis need to be mastered too?

Just got the fault sheet from the garage, they asked if I'd know anyone who might
know what all this points to....




Things do not look good for me unfortunately, due to circumstances beyond my control
I don't have any money to spend on the car (or anything, for that matter!),
so I'm just gonna have to park it for a while if it is the gearbox that needs to be rebuilt.

So now I will have 2 cars parked up awaiting funds, the S8 was my daily driver
so it puts me in a bit of a bind.

With all the **** that's happened in the last year I must be due a lotto win or something!

To fufill my curious streak however, does anyone know if the 01E DGV 6 speed
that was used in the D2 S8 was used in any other cars?

[Architex_mA8tey]

Here are the ross tech wiki outputs for those codes -

17118/P0734/001844 - Gear 4: Incorrect Ratio

Possible Symptoms
Clutch Slipping
Reduced Power Output

Possible Causes
Gear related Clutch slipping/faulty
Gear related Solenoid Valve dirty/faulty
Overloaded Clutch due to continuous high Torque or Tuning
Wiring and/or Connections faulty
Sensor Gear Position Indicator faulty
Mechanical Failure

Possible Solutions
Check Engine Values for Plausibility, especially Torque related ones.
Check Wiring and Connections
Check Sensor Gear Position Indicator
Check Gear Solenoides

Special Notes
The gear monitoring of the transmission control module checks the gear ratio by comparing transmission input and output speed in regard of the currently selected gear. This fault code is being set when recognizing an implausible transmission ratio.


17114/P0730/001840 - Gear Ratio Monitoring: Incorrect Gear Ratio

Possible Symptoms
Malfunction Indicator Light (MIL) ON

Possible Causes
Transmission Fluid contaminated
Transmission faulty (Mechanical Problem)

Possible Solutions
Check Transmission Fluid (Color and Contamination)
Replace Transmission Fluid when necessary
Check Transmission Mechanics

Special Notes
Transmission Damage may be caused by Engine Problems, make sure there are no other/relevant Fault Codes stored in Engine Control Module.
When found in 6-Speed Automatic Transmission (01J/Multitronic):
Instructions on how to check the Transmission Fluid as well as Details on a special Test Kit can be found in TPI 2016661. TPI 2006088 may also be relevant.
A conversion from 6 to 7 Clutch Plates may be possible. See TPI 2004856 for Details.


17087/P0703/001795 - Brake Switch (F): Electrical Malfunction

Possible Symptoms
Malfunction Indicator Light (MIL) ON

Possible Causes
Wiring and/or Connector(s) from/to Brake Switch (F) faulty
Brake Switch (F) faulty

Possible Solutions
Check Wiring and/or Connector(s) from/to Brake Switch (F)
Check/Replace Brake Switch (F)

Special Notes
When found in Vehicles with Drive-by-Cable (DBC) the Brake Switch (F) is connected to the Transmission Control Module. On older Models this Code is stored automatically after Terminal 15/Ignition is switched ON. If the Brake Switch (F) is OK you can avoid this Fault Code by pressing the Brake Pedal after switching on the Ignition and prior to checking Fault Codes. The Code should automatically be cleared then.
When found in Vehicles with Drive-by-Wire (DBW) the Brake Switch (F) is connected to the Engine Control Module In this case you should check the Engine Control Module for Fault Codes as well and the Data Bus Wiring between Engine and Transmission Control Module.


65535 - Internal Control Module Memory Error

Possible Causes
Control Module housing leaky > Control Module wet
Wiring from/to Control Module faulty
Control Module faulty

Possible Solutions
Check/Clean Wiring from/to Control Module
Replace Control Module

Special Notes
This fault is NOT to be ignored when found in a major and/or critical system (Airbag, ABS etc.).
When stored in other unimportant systems (Radio etc.) the general suggestion is to ignore it unless you notice functional limitations. Within the warranty period dealers are usually required to replace such control modules, but there have been a couple of cases with similar codes where these are getting ignored due to flaws in the control module software. If in doubt please refer to technical bulletins and similar documents provided by the vehicle manufacturer.
Audi Airbag 6 & 7
Problem: A fault of the acceleration sensor may result in the above fault.
Solution: Replace Airbag control module and both acceleration sensors.
Audi Airbag 8
Problem: Due to under voltage the control module does not complete it's self test successfully.
Solution: Replace Airbag control module and install a under voltage protection relay for it.
Certain older TDI ECUs which have a vacuum line going to them
Problem: Vacuum line broken, either before ECU or inside ECU.
Solution: Inspect and repair vacuum lines to ECU and inside ECU.


17114/P0730/001840 - Gear Ratio Monitoring: Incorrect Gear Ratio

Possible Symptoms
Malfunction Indicator Light (MIL) ON

Possible Causes
Transmission Fluid contaminated
Transmission faulty (Mechanical Problem)

Possible Solutions
Check Transmission Fluid (Color and Contamination)
Replace Transmission Fluid when necessary
Check Transmission Mechanics

Special Notes
Transmission Damage may be caused by Engine Problems, make sure there are no other/relevant Fault Codes stored in Engine Control Module.
When found in 6-Speed Automatic Transmission (01J/Multitronic):
Instructions on how to check the Transmission Fluid as well as Details on a special Test Kit can be found in TPI 2016661. TPI 2006088 may also be relevant.
A conversion from 6 to 7 Clutch Plates may be possible. See TPI 2004856 for Details.


I have to say it doesn't look good - 4th gear was what went on my recently failed box
If it is that then your only hope is for a rebuild or a service exchange box, or talk to A8 parts to see if they have any reasonable ones there.
Good luck with things . . . .