Project D2 S8 (FL) 01E Conversion.

[Nollywood]

Hello guys!

I've always loved big-engined cars, especially of the VAG variety. And last week, I picked up a peach of the D2 chassis - a 2001 S8 in Aqua Blue.

All in, a lovely car. It's marred by just one thing - it's Tip only in the UK. From what I gather, the German market got the 01E 6-speed manual, as far back as the PF models. The original Audi V8 D11 was also available with manual - 5-speed in 3,6, and 6-speed in 4,2.

I have started gathering parts for the conversion. I have just realised the driveshafts I have are off a C5 S6 manual. I also have my doubts as to the origin of the prop I bought from the same seller.

The Tip. 5-speed is a wider tranny, so running an 01E will mean the driveshafts will be too short. I don't want to cut and lengthen, so my approach is going to be different.

I am having distance pieces made up. These will be machined out of aluminium. 12 holes will be made - 6 will be non-threaded, and machined down to allow the OEM driveshaft bolts to go through, bolting the spacers to the 01E output flanges. The remaining 6 will of course be threaded, allowing the original driveshaft bolts to be bolted to them.

I'm going to borrow a vehicle lift, and measure the length of my current Tip. tranny, from engine mounting face to propshaft flange. This will give me the length required for the prop. If the Tip. prop is shorter, I'll employ the same approach used for the driveshafts. If too long, it'll have to be cut down, shortened and balanced.

The clutch pedal clearance issues with RHD cars has been well documented. I don't want to find out what's behind the "bulge" in the tranny tunnel, I don't like the sound of cutting it down, rewelding or bashing it flat either.

I'm looking at a different approach to the 3rd pedal issue. I'll keep you guys posted.

[Goran]

I too am desperate for a solution, especially for the pedal box without cutting any of the chassis. I'll keep my eyes glued to this thread. By the way I have a 6-speed propshaft off a 1998 German S8, I can measure it for you or bring it round if you want to take measurements, I'm only in south London.
This guy on German ebay still has parts if anyone is looking for other bits off a manual S8. Looks like he has driveshafts too if 1998 ones are the same as a Facelift model.
http://stores.ebay.de/B-K-Racing-Tei...=p4634.c0.m322
http://www.ebay.de/itm/AUDI-A8-S8-D2...item230f824d58
http://www.ebay.de/itm/AUDI-S8-D2-4D...item483f7ee6e9

I pulled off some part numbers off VagCat incase its usefull. Part numbers look the same going from a Pre-FL 1998 S8 to a FL 2001 S8.

1998 part numbers
(1) 4D0521101R propeller shaft / 6-speed man. gearbox AHC,AKH

1A 4D0407271K drive shaft with constant velocity joints left / 5-speed man. gearbox: AAH,AEJ,AEW, ACK 6-speed man. gearbox AHC
(1A) 4D0407451X drive shaft with constant velocity joints left / 5-speed man. gearbox: AAH,AEJ,AEW, ACK 6-speed man. gearbox AHC
(1A) 4D0407272K drive shaft with constant velocity joints right / 5-speed man. gearbox: AAH,AEJ,AEW, ACK 6-speed man. gearbox AHC
(1A) 4D0407452BXdrive shaft with constant velocity joints right / 5-speed man. gearbox: AAH,AEJ,AEW, ACK 6-speed man. gearbox AHC


2001 part numbers
(1) 4D0521101R propeller shaft / 6-speed man. gearbox AQH,AQF,AUW ARU


1A 4D0407271K drive shaft with constant velocity joints left / 5 & 6 speed man. gearbox APR,AQD,AQH
(1A) 4D0407451X drive shaft with constant velocity joints left / 5 & 6 speed man. gearbox APR,AQD,AQH
(1A) 4D0407272K drive shaft with constant velocity joints right / 5-speed man. gearbox: APR,AQD 6 speed man. gearbox: AQH
(1A) 4D0407452BX drive shaft with constant velocity joints right / 5-speed man. gearbox: APR,AQD 6 speed man. gearbox: AQH

[Nollywood]

^^^ Nice one, Goran.

I have a feeling the constant velocity joints of the 2,8 V6 and 3,7 / 4,2 V8 (non S8) might be smaller than that of the S8. I might be wrong, I'll confirm from Audi.

Sure, it'll be great to take some measurements from your own 6-speed propshaft. If my purchased one is the same, great. If not, I'll buy a regular one off A8 Parts, have it cut and welded to the correct length, and balanced.

I'm looking at a hydro-electro solution for the clutch actuation, with mechanical override, and have a chosen route already.

Feel free to PM me your Address, it'll be good to meet up, and go over things.

[Nollywood]

I've seen that advert from the German dude. He lists both left and right axles with the same part number. How can that be right?

To the best of my knowledge, the 6-speed 01E tranny is based on the 5-speed 016 as used in the Coupe quattro type 85, Ur quattro and 200 quattro. These trannies are ever so slightly offset, so the axles will be different lengths, slightly shorter on the differential cover side, from memory.

I might take some measurements from your 01E axles, if that's cool with you.

[ainarssems]

4D0 407 271 K comes up for both left and right side and is used for 6 speed manual gearboxes with AHC,AKH,AQH engines and 5 speed manual for AAH,AEJ,AEW,ACK,APR,AQD engines

[Nollywood]

Originally Posted by ainarssems

4D0 407 271 K comes up for both left and right side and is used for 6 speed manual gearboxes with AHC,AKH,AQH engines and 5 speed manual for AAH,AEJ,AEW,ACK,APR,AQD engines

That's awesome. I've just bought the pair off the German dude.

[Goran]

I just compared mine side by side, one is definitely shorter by a few cm.
I only bought half-shafts as the full shafts are too expensive from Audi, and even the half shafts were £211 each before vat!
Anyway, I'm sure the German chap made a mistake, they must be different lengths otherwise his car wouldnt have worked

My part numbers for half shafts are:
4D0407418
4D0407417

just checked on VagCat for a 1998 5 or 6 speed manual, part numbers are the same, so you should be ok with ones you bought:
1B 4D0407417 drive shaft with constant velocity joint inner left / 5-speed man. gearbox: AAH,AEJ,AEW, ACK 6-speed man. gearbox AHC
(1B) 4D0407418 drive shaft with constant velocity joint inner right / 5-speed man. gearbox: AAH,AEJ,AEW, ACK 6-speed man. gearbox AHC

[Goran]

Here is the coding according to ElsaWin. Digit no.4 is gearbox coding, 6-speed manual should be code = 1

[Nollywood]

^^^ Thanks Goran.

[Nollywood]

I think I'll only require your propshaft measurements, Goran. I have purchased the S8 manual axles from the German dude.

Or I may simply measure my current 5-speed tip, and compare with my 6-speed manuals, in terms of length.