There are no more OE S8 flywheels. Nollywood and I bought them all I'm afraid, however for a 40V the V6 parts bolt straight on, and the B5 S4 / RS4 flywheel and clutch should easily be up to the job. There are plenty of clutch options for the S4 too.
Gearbox mounts are tricky - they are £300 each and I've never seen any second hand. They occasionally turn up on proper D2 01Es in Germany but they are extremely expensive - £1000-odd.
The gearbox itself would either need to be a proper DGW 01E, or one from a C5 A6 if you're going to use the proper mounts (FTL is the good TDI one). The B6 gearbox doesn't have the mounting bosses on it for the D2 mounts.
Driveshafts and propshaft turn up on ebay.de occasionally. Apparently the D2 LWB propshaft fits if you flip it 180*.
Shifter mechanism is a big challenge as its closer to the original V8 or C4 S6 than anything modern. Also unobtanium.
Nollywood has discovered that the auto ecu does not behave well with a manual, even though it can be coded accordingly. He resorted to buying a brand new manual ecu from TPS for £600-odd.
And finally... the clutch pedal. Goran's mock-up looks feasible. I've been looking at an alternative solution too using B5 A4 bits, but there is still no simple option, and no actual working example yet for good reason.
The only way this will be cost-effective (ie cheaper than fixing the 5HP24A) is if you can do the work yourself and can afford to have the car in bits for a long time while you wait for all the parts to turn up on ebay.de and fabricate the clutch mechanism.
If you can't do this work yourself and have to pay someone to solve all the little niggly problems along the way you're going to spend more on garage labour alone than an auto rebuild will cost. That's not even counting the cost of the parts which, if you do it properly is at least a couple of thousand.
What exactly is wrong with the auto? Some of the problems can be caught and fixed relatively cheaply before a full rebuild becomes necessary.
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