2002 VW Jetta automatic to manual transmission swap

This is an overview and timelapse video of one of my recent projects; I swapped a manual transmission into my 2002 Jetta TDI. The automatic transmission was beginning to slip, and this was the best solution I could come up with. It wasn't too bad; I was able to accomplish the swap in one full weekend.
Link to the swap instructions here:
pics.tdiclub.com/data/517/Boer...

[@mcleanmartel]

Excellent work. Way to shout out to boraparts. You made a good choice holding on to that Jetta. You live in a beautiful part of the country; different than here in Arizona!

[@leningchavez5730]

how much did the swap costs?

[@yabs9642]

my trans is finally starting to slip, luckily this video taught me a few things about swapping to manual. good job & thank you for the vid!

[@heroswrd]

you should have uploaded the whole thing for people can actually perform the project themselves.

[@rhinoxman515]

Great video by the way! I enjoyed seeing the time lapse and seeing it come together!

[@jeepcollector91]

Nicely done. I have an '03 Jetta that I am using as a 1.9L ALH engine donor for a '91 Miata. I was planning to sell off the remaining parts individually and didn't even think of selling parts for a complete manual transmission swap kit. I guess I didn't think there was enough people wanting to swap to a manual in the US.

[@peters1821]

Thank You! I got it now!! Works good! Had to change the fuel quantity a bit, but it's all good now! Thanks again!

[@rybar37]

I have the exact same car. I love it, but i'm having the same issues and will be looking to do the same. Good job!

[@kdoran709]

awesome! im about to begin this with my mk4. muat be a great feeling once completed and driving smooth

[@phooesnax]

You hear folks say....oh just toss an engine in or a trans n....haha. That looked like a ton of work and very well done.

[@Badgertronix]

Nice video and great job. I managed to overhaul my 01M valve body before it started slipping and it runs great. About to do a manual conversion on the car anyway for a fun project.

[@cbcalkins8620]

Badgertronix At how many miles ?

[@Badgertronix]

Charles Calkins 160,000 give or take. Thing runs great now

[@HalfassDIY]

You make that look so easy !

[@_Pet_Tech]

I've got MK4 Golf 1.6 with 01M that started slipping in 4th gear at operational temperature. Even though the car has 320000Km the engine and everything else feels rock solid. Soon I might be doing a manual swap.

[@michaelshone2465]

wow.... that was awesome!! I have a low mileage (42k) 2002 TDI Beetle up here in Central Ontario Canada and I plan on doing this when my auto finally dies, as I'm quite attached to my car. I dont have a hoist or anything though so I have a feeling I'll be paying someone to swap the O1M. Although hopefully my auto still has quite a lot of miles left in it.(unfortunately, as I'd love to swap now) Although with these transmissions... you really can never know for sure how long they are going to last! Loved the video though. Fantastic job! Definitely jealous. PS, now you also have a very valuable set up that many stock manual guys list over. A 5 speed and pricey 11mm injection pump that came stock with the auto compared to the standard 10mm pump that came in the manual cars. Makes the 11mm pump cars a little louder since they have smaller nozzles, but certainly a cool setup now thats for sure!

[@MattVerley]

Michael Shone Thanks! I wasn't aware that the auto cars had a different pump...good to know! I had planned on doing some research on power modifications in the coming weeks. I'm an experienced wrench turner on 12 and 24v cummins engines and also have some experience with 7.3 and 6.0 powerstrokes, and have fully built two older 1.6L VW diesels, but the ALH TDI is a new engine to me.

Chapeau bas Matt. Your Jetta got a new life :)

[@HYBRIDBATTERYSHOP]

Great video, about to do a swap and this video is a huge help. Thank you!

[@Engineerboy100]

Beast mode mechanic! I'm jealous of your shop! Beautiful good job on the video, Thank you

[@MattVerley]

Thanks! I'm just a hobbyist, but I really do enjoy taking on bigger automotive projects like this tranny swap. I have a few other engine/tranny/suspension swap videos out there. Most of them Suzuki related...this was my first transaxle swap. But, it came out well! No problems with it after almost 2 years.

[@Engineerboy100]

I'm self taught too and love it. You did a really great job covering the project, fun to watch.

[@stephensingh1242]

What did you wire the safety switch to

[@THEGREATONE420]

clutch switch gets wired to relay 53.

[@Engineerboy100]

Good Job! Great video, I'm gonna have to do this on a 2003 Beetle this helped.

[@austinhalstead8449]

Hey there what web sit was that kit from going to swap my gti to a manual 6 speed can't find no kit anywherev

[@TheRealDaveCast]

Where did you say you got the kit from?

[@jameshager1255]

Thank you for ....I have a 2003 JETTA I need to swap out..Where did you purchase????? KIT

[@Happy-Me.]

Great video. VWs last forever!!

[@abrahamgarcia8813]

A la gran!!! Very well done. I'm so jealous that I will do just the same with my 01 Jetta. Thanks for sharing

[@abrahamgarcia8813]

sewerzuk did you have to program the computer at all?

[@brezzyscopes541]

Looks like you did a great job! I was just wondering if I could switch my 7 speed automatic, to a 6 speed manual transmission on my 2012 Infiniti G37 x and you know around how much it would cost?

[@darewow4966]

on passat b4 i change the transmission from automatic to manuel and the abs and esp fault??

[@JiggaOfficial]

Hey i just did the conversion but still using my old starter was told youd have to trip it ,do you know how?

[@wxlfsjb4806]

How did you get dutch auto parts to send you the transmission parts

[@AK4739]

Beautiful work !!! I did the swap on my 02 Passat v6 TDI, the mechanical part was fine but I'm still having issues with the ECU having no response from the TCM, any clue ?? Thanks

[@mastermoarman]

hey awesome swap. im going to be doing the same on 03 jetta wagon. did you have to do any mods to the wire harnes or reprogram the computer?

[@lewiemcneely9143]

Good Job! But as exacting as you are on generators and other things it was not much of a problem for you. I felt for you on the add-on's though. You never know, as you said but it worked out really nice!

[@peanutbutterisfu]

Like to add the power steering pressure line is different from auto to manual , they make 2 different power steering lines for manual Transmissions one with a/c and one without, the most common is with a/c and it’s cheapest to buy on eBay $100 for a sunsong brand (most aftermarket hoses use this company and put it in their box). Also the brake pedal is hard to get off even if you have the special tool. You can cut the pedal down, the automatic pedal just has a plate welded to it or I would buy a new clip for the pedal on eBay for 6 bucks it saves a bunch of time just to replace the clip and break the old one. If you need the connectors for the Transmission cables eBay has the normal pin style but if you need the socket style ecs tuning is the cheapest at about $45 shipped for 2 of them. The connectors are called “Bowden cable catch”. I have a pick and pull junkyard in my area, I was able to get the clutch pedal assembly, master cylinder, hose, switches, brake pedal, shifter with cables, bolts, Transmission mount for under $45 bucks so I would highly recommend going to a pull it yard. All my stuff was taken from a beetle. I do a lot of work on these cars so I had some of the other stuff laying around and bought a Transmission with 70k miles off a customer for 300. I’d say I’ll have about 600 bucks or less into the swap. I did use a dual mass flywheel and clutch but only because it came with the Transmission and was in 90% good condition but i also am a mechanic by trade and have a lift at home. If your paying someone to do this job or doing it on your back I would get the single mass conversion kit. This is a good video, a lot of other videos aren’t 100% on what you need.

[@GMRone]

Nice video. One question. Can so the swap with automatic module..and wiring?..

[@alexpena9078]

Where did you get the kit for the manual I have a 2003 Passat 1.8t auto

[@Continental719]

What was the name of that place you ordered your transmission kit?I want to swap my auto into a 6sp manual, and swap my 2.0L into a 1.8T

[@brandonrobishaw7606]

That's a great project. You couldn't get a sunroof and stick shift together from the factory, and depending on the year power windows. An additional benefit would be now you have a larger injection pump and injectors than would come with the manual. Originally to overcome the torque converter power draw. Enjoy your TDI the automatic transmission was your weakest link.

[@240retop]

We're did you buy all the pieces for the swap???

[@cfrc9362]

Looking for some heads up... I have a 2004 jetta 1.8t automatic, i also have a donor vehicle 2004 jetta 1.8t manual. So far I understand that everything should fit with no problems, my only concern is the speedometer and the rpm, since I swapping tranny what do we need or what I dont need to have the whole dashboard working?

[@charissarobinette7411]

Is it possible to do this without a lift? I need to take the transmission out of my 04 jetta manual and put it in my 06 jetta automatic

[@ethanwinkel6012]

Hey noticed you are from oregon. I am also from oregon and will be doing a manual swap on a mk4 2.0 and was wondering if there was a way I could ask you a few questions about the swap.

[@benirharizi2128]

Hello Please can you explain me i want to change the transmission automatic on manuel but my transmission is 1.9Tdi 130cv and the manuel is 1.9Tdi 115cv ,now is same for change or not please .

[@mimmormino]

So is there any difference when bolting a manual to automatic engine. Is the crank compatible for both transmissions.

[@shawnmrfixitlee6478]

Great vid , Good swap man !

[@kevincorrales4497]

Hi. I have a couple of questions . I own a 2000 beetle and 2002 jetta . both 1.8t jetta automatic transmission .need to do same as.you but .what about the connection to automatic to manual wires? won't affected the computer.

[@racoonzattack]

Would you recommend repairing an automatic on my 2005 MK4 Jetta 2.0 GLS or swapping it out for a manual? According to the vw mechanic the transmission differential broke after I described a mechanical clunking sound at about 30 mph. The car has approx 104k miles on it. I'm looking for the most affordable option but will consider a more expensive one if it means adding life to the car. Appreciate your feedback! And great video!

[@ESEMCSTILO402]

does this transmission work for a 1.8 turbo engine? i have and Auto that i hate i would love to do this

[@austinhalstead8449]

Would this be the same for a 2008 va gti and how much did everything cost

[@ThaHammieJaassee]

sewerzuk do you think this is possible on a 1985 golf?

[@christopherwilliams9418]

Looking into doing this when I finally get myself a Beetle. Gonna' find a cheap auto, drive it 'til the transmission dies and swap in a manual. Not sure which engine I'm going to get, but might engine swap whatever's in it too depending on how finances look. If I go through with it, I'm a little torn between doing a VR6 swap, or the 225 hp 1.8T out of a TT quattro. Maybe if I win the lottery I'll have it converted to AWD as well. :P

[@34lanesboro]

the tdi 02j manual trans will fit in a mk4 2.0gasjetta correct?

[@hectorramirez1115]

can i say im all set, if i got a working car (motor and manual transmision) and i want to swap into my automatic transmission car? what else should i considered? thank you, goood job!

[@mikeramirez8117]

Do you know a website where I can get a manual swap kit for a gasoline engine ?

[@angelvizcaino1759]

would this be the same process for a 1.8T on a 2005 GTI?

[@krazyhand1653]

I have a 2011 Jetta 2.5 SE. How much do you think it cost the conversion from automatic to manual in that car?

[@ryanlogan2911]

Any chance to do a 6sp swap in the older 1.9 TDI cars like this?

[@SGTPJ]

beautiful video man, i just picked up a 99 gold gls 2.0 with 30k miles and my goal its to do the same once the transmission goes out long way to go tho :)

[@tjburgoyne8909]

Did you ever swap,?

[@ke6bnl]

I want to do things a little different, I want to save my 2002 tdi autotrans and buy a MK4 manual TDI, can I use my low mileage 2002 tdi in the manual car as a direct bolt in, in the future??

[@gunguy2808]

Hey did you just use the same ecu ? Plz respond I see you pulled out the tcm how was that ? I know that this is 7 years old but I need to get this transmission done and idk what I gotta do for wires

[@MyJeremy79]

Did u have to do any wiring to keep check engine light off

[@lmandsons]

what was the total cost of the swap new and used parts?

[@fernandocruz8594]

I got one Golf GTI 1.8 my transmission is broke can you tell me how much it cost for swap the transmission please

[@kalebalexander2852]

Is this the same trans thats in the mk3 Jetta 2.0

[@slipperyslope3912]

This might have been the most enjoyable tranny swap video I've ever seen. My only use for music would be to cover up all the cussing!

[@Tahimate]

Do you have information on any rewiring?

[@carlosmendez5477]

Where can i buy the transmission swap?

[@DougHanchard]

Good job. Too bad you didn't make a series out of this swap. I hear that some of the swaps many are now doing are 6 Speed manuals. The biggest knock against Tiptronic and DSG's isn't really the transmission design (relative to other makes). Its all a matter of maintenance. Changing oil regularly in the trans is a must or it will burn up. It is true that the frequency of the change of fluid is much shorter than traditional expectations. 50,000 miles is pretty much mandatory. Solenoids get gummed up pretty easy too.

[@Isaac72696]

It works the same on a 1.8T Jetta?

[@fishmishin]

Nice video, great shop !!

[@erikaguilar1059]

You didnt have to do anything to the ecu? Just run power to the clutch to give it power for the clutch switch?

[@gim9185]

i just swaped today to manual my pasat b5.5 and i think it runs good but is it worth it

[@briannamartinez7469]

Did you have to recode the ecu from auto to manual after the swap? Or how did you get passed that? Sorry i know this is from 2015.

[@chaddavis2543]

I have a 2001 1.8t Jetta. What transmissions fit in my car?

[@thanhnguyen4908]

so did u end up reflash or re-coding from ECU, ECM auto trans to switch over coding with Manual Trans ???

[@Samll19821]

Nice work man I opened the link for how to wire the sensors but is too complicated for me I just need to make it work the speed sensor and the reverse sensor do you have an other easy way to make those work? 03 jetta tiptronic to a manual 5 speed thanks have a nice day.

[@FenixPajarito]

I have a 2004 GTI 1.8t It used to be Tiptronic Transmission, but a friend of mine swapped a Manual 5 Speed Transmisión, everything worked perfectly after the swap except the Speedometer, did he made a mistake with the wiring harness? RPM And all the needles work except the speedometer.

[@broed731]

thank god, a car video without edm in it lmao

[@kenjitakashima]

Nice helpful vid! I'm also looking into swapping my automatic transmission to manual for my 2005 lancer . I really don't wanna sell the car but the costs so far is quite pricey. Is there any way of swapping it without costing me a lot.

[@bryanbuckley2747]

Great vid I am wanting to do this with my 05 golf

[@algimube87]

HOW DID YOU MAKE WORK DE SPEEDOMETER??? HELP PLEASE!!

[@rootsdat]

Great work bro

[@kurtallicock4505]

Hey where did u bought your conversion kit am looking to do the same thing with my vw golf 2004 model

[@MattVerley]

Kurt Allicock www.dutchautoparts.com/ I had them send me all of the used parts; I bought a new clutch/flywheel and a few other small parts from Bora Parts.

[@johna.4334]

Great video. Note: Do yourself a favor and upgrade the front brakes to the MK4 GTI rotors and calipers. You'll see a huge improvement in braking.

[@nicolaszamora6899]

I have a Volkswagen jetta gli 05, left it in the shop to get a swap from automatic to standard. When they do the swsp, they do they change the Axel?

[@aygwm]

Yep, auto and manual axles are different., as are the axles between 4-cylinder and VR6s.

[@phillipdorofy5149]

Hey great work i am currently doing a swap on my 1.8t but i need help. How did you manage to recode the ecu from auto to manual? right now i got the manual in and everything drives fine but my speedometer doesnt work and i got an engine light on.

[@MattVerley]

Phillip Dorofy The speedometer should work fine without any changes in the ECU; the connector for the auto and manual speed sensor is exactly the same. It just plugs right into the VSS on the new transmission. The VSS is in a slightly different location; closer to the firewall. As far as the re-coding goes (necessary to clear the CEL and make cruise control work) you need to find somebody with VAG-COM to plug in and re-code it for you. It's quick and easy...just a few minutes. You can usually find somebody close to you by just asking in one of the VW forums, but here is a locator with links to people who have volunteered the use of their VCDS software to those who need it: www.maptive.com/ver3/VCDS_Locator

[@nishantluthra6978]

Did your instrument cluster worked post the swap .(RPM and speedometer) ? if yes kindly guide me with the wiring changes you made. thanks.

[@MattVerley]

yes, it works fine. There is a link to the instructions in the video description

[@kevincervantez3867]

Sick video!

[@Tahoe0512]

What is a name of this guy or company that you have swap kit from? Where did you get transmission from?

[@Continental719]

I heard that any o2j transmission can be used with any 4 cyl engine VW mk4 from 00-05

[@mykhailo7172]

Awesome video!

[@00wtfo00]

great vid, and thanks for the pdf added info as well! have you already, or planning to do the euro 5th gear swap in your trans?

[@fuckjewtube69]

How much was the parts for the swap?

[@marentesvic65]

hi,what up the computer things?

[@cbcalkins8620]

You are very knowledgeable :)

[@hectorgbay]

could you explain in brief some of the wiring you did for the tcm and ecm. and how you got the car to start with a automatic ecm id really apriecate it!

[@MattVerley]

+Hector Garibay Basically, I just unplugged the TCM for the automatic and let the harness dangle. The car will start/run/drive this way, but cruise control doesn't work and the MIL stays on. The ECU needs to be re-coded for manual transmission (easily done inside of VCDS), and a "clutch disengaged" +12v signal needs to be sent to the ECU. Those are the only real changes; details on the pins used are in the swap guide: pics.tdiclub.com/data/517/Boertje_Auto_to_6_spd_manual_swap_and_wiring_instructions.pdf

[@phillipdorofy5149]

Hi I do have a vag com from Ross tech but every time I change the engine coding it does not take. It reverts directly back to the old coding. I read somewhere that you may need to acquire the skc? If this is the case did you have to acquire one? If so how? Also the prior trans was a 5 speed tip tronic auto and I swapped to a 5 speed manual o2j I believe. The connections aw completely different. Will I have to retire these. Thx in advance for any time you have given to reply:)

[@MattVerley]

Phillip Dorofy Hmm...well, this sounds like a problem that I don't know how to fix! Probably best to ask it one of the forums...

[@chikoraro]

I have some question's if u can help me out

[@rhinoxman515]

Where did you get all of the parts for this? In the video you said you got a lot of the parts sent to you from Dutch auto parts? How much for everything besides the manual trans?

[@MattVerley]

Total cost was about $1400; this includes pretty much everything seen in the video, including the transmission and all conversion parts, clutch and flywheel, gear oil, seals, etc. I ordered the trans parts from Frans at Dutch Auto Parts; communicated with him via PM on the TDIclub board. He was good about returning my messages, and the parts shipped quickly.

[@randallsmith7022]

what did you use to swtich from auto to manual in the computer? I did the swap in my 2002 Jetta with a VR6 12v I put in a 02M 6 speed and now have codes due to it being manual and it is still shwoing auto in the PCM.

[@MattVerley]

I used the vag-com software, and there was also a wire that needed to be moved on the ECU. I'm not sure if your VR6 would be the same...

[@billyowusu48]

Is this very costly because my transmission is bad

[@LordsNeverWorry]

Bro you did that shit so effortless

[@Liam_Michel]

Hey just curious of where you got the manual transmission from and how much it cost you approx ? Thx

[@Liam_Michel]

Hey never mind haha . I eventually made my way into the depth of the comments