What's in the workshop? Its manual swap time!

[ainarssems]

Return at the back (apologies for the focus ). I need to make another support halfway along this when I build the exhaust support bracket. On the next ones I might actually use the C5 return hardline at this point and join the hose where the pump union is.

Using C5 pipes is what I was thinking.

Just to think when I was buying new radiator for C5 a year or 2 ago everybody in 2 different shops was telling me there is no radiator with integrated gearbox cooler for manual boxes, just auto. I think cooler is only for cars with 180 HP??, could be wrong. Anyway after having 5 wrong radiators supplied in 2 different shops even supplying reg number and Audi part number ( no gearbox cooler, pipes in wrong locations and wrong diameter pipes) I finally gave up and ordered one from Germany, cheaper (£80) , right stuff and arrived in 3 days

[MikkiJayne]

Yes, from the 180hp 2.5TDI, and also the 2.7TT as well I think. They won't work directly in a D2 V8 since the C5 has them in the radiator on the driver's side and the D2 is on the passenger side, but I can use most of the return hard-line to save having a long run of hose

[MikkiJayne]

The engine and gearbox are ready so on to the internal bits.

Don't need this any more



Space for the new shifter



A6 shift lever on a custom bracket. This bracket is 'knife & forked' from flat plate and angle section. The production run will be CNC'd and folded.



The other half of the shift levers. Autofocus on the Oneplus One sucks btw.



Fitted in the tunnel with the protective boot (this is an adapted A6 boot btw since the D2 one of course is NLA)



Shifter in place



Shift rods from the tunnel



They attach to these



I split the shifter rods using some custom turned adapters so that they can be split at the back of the gearbox from under the car. This means you don't have to pull the centre console out to remove the engine. I'll show how this goes together when the engine & box go back in.

On to the pedals.

Conveniently, whoever designed the firewall on the D2 didn't get the message there wasn't going to be a manual RHD version, so they put a place for the clutch hose to go through the sheet metal This is pretty much a mirror image of where it is on the LHD models.



Hole drilled and a pull-through, er, pulled through



This is where the hose will come through the sound deadening.



and this is where it all went a bit Pete Tong. I bled the clutch master cylinder on the bench before fitting it to the car, and while I was doing so discovered that the seals had failed I think operating it dry while I've been designing the pedal has trashed the internals and so it can't create enough pressure to operate the clutch fork. I can't get a new one until Tuesday.

Bugger

Mike's Murple is in on Monday for an engine-out service so the swap has to go on hold while we do that. Its unlikely I'll get any time to finish it off before Germany now.
So close...

[MikkiJayne]

This is nearly complete so I thought I ought to update the thread

I sourced a replacement clutch master cylinder and bled the complete system on the bench, then removed the slave and capped off the hoses. Put everything back in the car, reattached the slave and bled it again. This time it worked with a nice solid pedal.



Hose routing.



Clutch switch for the cruise control



Slave cylinder. I re-used some heat-shielding from the wiring harness as the hose runs a bit close to the downpipe.



Driveshaft - new v old



Engine and box going back in





Loads more room in here now



The clutch slave is a total **** to get to with the engine in! Much more so than in the A4 or A6, simply because the superstructure of the D2 is so much more bulky.



After a successful test drive I started putting the interior back together. I've lost a bunch of pics, but I printed an adapter piece to fit an A6 gearstick gaiter in to the D2 console trim which looks like this:



Installed it looks like this:



I also removed the tiptronic steering wheel and replaced it with a manual version.

[27litres]

Wow!
Looks like it grew there Michaela!
Nice job!

I like the detail with the removal of the tiptronic steering wheel!

Your little details printed up on the 3D printer add to the fit and finish too.

[Architex_mA8tey]

Awesome job MJ - this is a triumph of skill and care

[RICKY D]

Huge respect MJ

Looks so good!.....when are you taking orders?

[tintin]

Awesome. Truly awesome.

[Regulus]

That is some piece of craftsmanship

I sincerely hope you feel that all the work you have invested, to be able to do the conversion, has been worth the time and effort.

In any case, you do prove time and time again - that hard work and commitment beats anything the schools can offer in terms of education and skill acquirement!
You should have an apprentice who wish to learn the trade the old fashion way

[tonupkid]

Truly impressive. Not just the build but also the way you've completed those important cosmetic details