Manual swap a8L

[Fredde]

Hello I am planning on swapping my A8lwb to manual and I am wondering if the 6 speed from A4 b5 Quattro 1.9 tdi would work? The part number starts with 01E but is this some inferior 01E because of it being bolted to a small tdi? Or should this be fine? Reason I want to use the 1.9 gearbox is because I found a complete car for sale for 250£ so i would easily make that back selling parts and then have a almost free gearbox and diff combo. Also I am wondering if anyone knows how the lwb driveshaft is extended when compared to a swb shaft.Do I need to get it lengthened and balanced or are there any cheaper options with spacers different driveshaft or something like that. Clutch I read b5 s4 clutch and flywheels would work can anyone confirm this? They are pretty cheap and would like to cut costs as much as possible without compromising quality to much. I also found a guy selling oem d2 manual pedal cluster, front driveshafts, shifter linkage, gearbox mounts and clutch line so those are good.

[MikkiJayne]

Are you sure its a 6-speed? According to the data and my experience the B5 1.9 TDI is a 5-speed 01A. The 01E only came with the 2.5TDI in the B5. It wasn't paired with a 1.9 until the C5 and B6 with the PD130. Also the B5 diff is different to the D2. The ideal donor is the A6 C5 2.5TDI, or possibly a B6 1.9TDI although they have odd output flanges.

I've done a swap in an S8 with a TDI 01E and its ok, not great. 6th is just a bit too high, meaning it does about 1600rpm on the motorway and while that is great for fuel consumption, having to change down to accelerate gets tedious.

You would have to have your propshaft extended since there is no LWB manual from the factory. In theory you could bolt the front of a manual shaft on to the back of a LWB shaft, but manual shafts are extremely rare. Easier to extend it if you can find someone capable of doing it.

S4 stuff does work, but you'll need the spacer between engine and gearbox which will also impact the propshaft. TTV Racing in the UK make a flywheel to take a B5 RS4 clutch which doesn't need the spacer - that's what I've used in the past, and the RS4 clutch is quite cheap. Get the heavy flywheel if you go this route.

The only other thing to bear in mind is that you'll need an S8 manual map in the ECU since there is no manual map for the A8 4.2. This means also swapping to the S8 inlet manifold and throttle body, injectors, and airflow meter so the ECU knows what is going on.

[Fredde]

Here is a link to the same gearbox that is in the car in looking at https://www.bildelsbasen.se/en-se/pb...67/01E300048CX Code is EHW seller says its 6 speed and when looking up the reg on databases they list it as 6 speed so I think this is correct that’s to bad about the diff but sourcing one of those cheap should be no issue. I assume it would have to come from a manual? I have a tig welder and some skills so I think I will be extending the driveshaft myself and having my machine shop balance it. Interesting to hear about the rpm on highway and I think that would be great for my driving style. That TTV flywheel sounds pretty good and I think i will use that any noise issues with the single mass design? Also do you know what they cost? Couldn't see price on on their website. I have the tools to tune most Audi’s and maybe a custom map could be made to make it work? I would prefer not having to swap the s8 stuff over since that sounds expensive but have not looked in to it yet or would it increase engine performance? If I’m gaining hp that would be a different case

Originally Posted by MikkiJayne

Are you sure its a 6-speed? According to the data and my experience the B5 1.9 TDI is a 5-speed 01A. The 01E only came with the 2.5TDI in the B5. It wasn't paired with a 1.9 until the C5 and B6 with the PD130. Also the B5 diff is different to the D2. The ideal donor is the A6 C5 2.5TDI, or possibly a B6 1.9TDI although they have odd output flanges.

I've done a swap in an S8 with a TDI 01E and its ok, not great. 6th is just a bit too high, meaning it does about 1600rpm on the motorway and while that is great for fuel consumption, having to change down to accelerate gets tedious.

You would have to have your propshaft extended since there is no LWB manual from the factory. In theory you could bolt the front of a manual shaft on to the back of a LWB shaft, but manual shafts are extremely rare. Easier to extend it if you can find someone capable of doing it.

S4 stuff does work, but you'll need the spacer between engine and gearbox which will also impact the propshaft. TTV Racing in the UK make a flywheel to take a B5 RS4 clutch which doesn't need the spacer - that's what I've used in the past, and the RS4 clutch is quite cheap. Get the heavy flywheel if you go this route.

The only other thing to bear in mind is that you'll need an S8 manual map in the ECU since there is no manual map for the A8 4.2. This means also swapping to the S8 inlet manifold and throttle body, injectors, and airflow meter so the ECU knows what is going on.

[Fredde]

Actually just looked on eBay and found a 40v s8 inlet manifold with TB injectors included for 280£ so not that bad

Originally Posted by MikkiJayne

Are you sure its a 6-speed? According to the data and my experience the B5 1.9 TDI is a 5-speed 01A. The 01E only came with the 2.5TDI in the B5. It wasn't paired with a 1.9 until the C5 and B6 with the PD130. Also the B5 diff is different to the D2. The ideal donor is the A6 C5 2.5TDI, or possibly a B6 1.9TDI although they have odd output flanges.

I've done a swap in an S8 with a TDI 01E and its ok, not great. 6th is just a bit too high, meaning it does about 1600rpm on the motorway and while that is great for fuel consumption, having to change down to accelerate gets tedious.

You would have to have your propshaft extended since there is no LWB manual from the factory. In theory you could bolt the front of a manual shaft on to the back of a LWB shaft, but manual shafts are extremely rare. Easier to extend it if you can find someone capable of doing it.

S4 stuff does work, but you'll need the spacer between engine and gearbox which will also impact the propshaft. TTV Racing in the UK make a flywheel to take a B5 RS4 clutch which doesn't need the spacer - that's what I've used in the past, and the RS4 clutch is quite cheap. Get the heavy flywheel if you go this route.

The only other thing to bear in mind is that you'll need an S8 manual map in the ECU since there is no manual map for the A8 4.2. This means also swapping to the S8 inlet manifold and throttle body, injectors, and airflow meter so the ECU knows what is going on.

[Fredde]

This guy swapped his a8L and just mentions sending his ecu out to be recoded. No parts swapping so seems it may be possible. I asked the tuning file supplier I use and will see if they think they can do it. https://www.audizine.com/forum/showt...eed-swap/page3

[MikkiJayne]

So, interesting - EHW goes with the PD115 engine in the B5, for one year only, mainland Europe only. I'll get my coat

That has a 4.111 rear diff so from the D2 range you would need an EUU which is the S8 diff, although confusingly the data shows the A8L may also have that so you might not even need a diff.

Also interesting, with a 4.111 diff, that 01E might not be too high geared so may well work nicely. The only downside of it is that it is the small sump version without an external oil cooler. All of the high torque applications of the 01E have a larger sump under the diff and a diff-driven oil pump to an external cooler.

The only A8 4.2 I know of with a manual swap used the S8 bits in order to use the S8 file, but it is entirely possible to make a manual map if one is suffciently skilled. It just tends to be rare and expensive, but if you can do it then go for it

The TTV flywheel was £370 last time I bought one. It may be a little more by now. The RS4 clutch is under £200 I think. The S8 original manual flywheel is single mass so the heavy TTV works fine. There's no need for a dual mass.

[Fredde]

Ah i Will check my pr codes what diff i have. Is the small sump no oil cooler thing an issue? Would i have to retrofit something or would it work anyway?

Originally Posted by MikkiJayne

So, interesting - EHW goes with the PD115 engine in the B5, for one year only, mainland Europe only. I'll get my coat

That has a 4.111 rear diff so from the D2 range you would need an EUU which is the S8 diff, although confusingly the data shows the A8L may also have that so you might not even need a diff.

Also interesting, with a 4.111 diff, that 01E might not be too high geared so may well work nicely. The only downside of it is that it is the small sump version without an external oil cooler. All of the high torque applications of the 01E have a larger sump under the diff and a diff-driven oil pump to an external cooler.

The only A8 4.2 I know of with a manual swap used the S8 bits in order to use the S8 file, but it is entirely possible to make a manual map if one is suffciently skilled. It just tends to be rare and expensive, but if you can do it then go for it

The TTV flywheel was £370 last time I bought one. It may be a little more by now. The RS4 clutch is under £200 I think. The S8 original manual flywheel is single mass so the heavy TTV works fine. There's no need for a dual mass.

[Fredde]

Hey sorry for all the questions but a standard a8 40v with the s8 intake manifold, TB, injectors, and MAF would that work well with the s8 map? Afaik the s8 also has different cams and exhaust manifolds would those not be needed to make the s8 map work? Been reading up on the whole manual ecu tune thing and using the s8 parts and tune is starting to sound like the simpler option. Another thing is a manual swapped car is not actually supposed to be able to pass Swedish MOT so I may actually end up being forced to do a engine swap as well to register the car as a “modified vehicle” but if that is the case I will be building myself an d2 S8L altho finding a 40v s8 engine for a price less than I bought the car for doesn’t look to easy.

Originally Posted by MikkiJayne

Are you sure its a 6-speed? According to the data and my experience the B5 1.9 TDI is a 5-speed 01A. The 01E only came with the 2.5TDI in the B5. It wasn't paired with a 1.9 until the C5 and B6 with the PD130. Also the B5 diff is different to the D2. The ideal donor is the A6 C5 2.5TDI, or possibly a B6 1.9TDI although they have odd output flanges.

I've done a swap in an S8 with a TDI 01E and its ok, not great. 6th is just a bit too high, meaning it does about 1600rpm on the motorway and while that is great for fuel consumption, having to change down to accelerate gets tedious.

You would have to have your propshaft extended since there is no LWB manual from the factory. In theory you could bolt the front of a manual shaft on to the back of a LWB shaft, but manual shafts are extremely rare. Easier to extend it if you can find someone capable of doing it.

S4 stuff does work, but you'll need the spacer between engine and gearbox which will also impact the propshaft. TTV Racing in the UK make a flywheel to take a B5 RS4 clutch which doesn't need the spacer - that's what I've used in the past, and the RS4 clutch is quite cheap. Get the heavy flywheel if you go this route.

The only other thing to bear in mind is that you'll need an S8 manual map in the ECU since there is no manual map for the A8 4.2. This means also swapping to the S8 inlet manifold and throttle body, injectors, and airflow meter so the ECU knows what is going on.

[MikkiJayne]

The cams aren't needed, or the exhaust manifold. Its just the electronic parts so that the S8 ECU program works properly. It will adapt to the reduced air demands of the A8 engine by putting in proportionally less fuel. I'm guessing you're in touch with Mario to get the clutch pedal, driveshafts etc? He's the one who came up with this recipe for making a manual A8 so he may be able to tell you a bit more about it.

I didn't know Jeremy had a manual A8L - have you asked about his tune?

A friend is doing an S8 swap in to an L so that he can have manual, rather than going Mario's route so there are a few options.

[Fredde]

Aha that makes sense about the cams ow yeah I will check with Jeremy since he just mentions sending the ecu out to be tuned not by who maybe whoever did it can inform me the guy selling the swap kit is called žymantas Juškevičius so I don’t think he is mario. But the s8 engine with s8 tune should be plug and play right? Does your friend have a build thread one could follow for guidance?

Originally Posted by MikkiJayne

The cams aren't needed, or the exhaust manifold. Its just the electronic parts so that the S8 ECU program works properly. It will adapt to the reduced air demands of the A8 engine by putting in proportionally less fuel. I'm guessing you're in touch with Mario to get the clutch pedal, driveshafts etc? He's the one who came up with this recipe for making a manual A8 so he may be able to tell you a bit more about it.

I didn't know Jeremy had a manual A8L - have you asked about his tune?

A friend is doing an S8 swap in to an L so that he can have manual, rather than going Mario's route so there are a few options.