
GermanAutoConnection's Automatic to 5-Speed Conversion Process
Overview
(Caution: Please see disclaimer at bottom
of page)
Custom Conversion Index
GermanAutoConnection is an authorized
034EFI Motorsportsä
distributor
Below is an overview of the process, a general list of required parts, and a few photos
of the long (but rewarding)
process of converting an automatic to a 5-speed stick, including extensive
remodeling of the transmission hump. Other pictorials are listed on our
Custom Conversion Index
Caution: Not a job for the faint of heart... J
TECHNICIAN'S COMMENTS: "I would like to point out that the
transmission tunnel is a major structural member in a unibody car. Mess up
a mod like this and a car will quickly gain several very annoying squeaks
and rattles, or worse (see
disclaimer). This is a major reason why it took me a long time before I
made the first cut into Steve's 93. The patch I made to his tunnel
is probably overkill but I knew when I was done that it was stronger and
more rigid than when factory new."
- Keith
Read a happy customer's testimonial about our Audiä
5-Speed Conversion.
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Major work (Steve B's '93 Quattro 4.2 V8 featured here):

 
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Remove transmission controller and associated
wiring
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Fabrication of new transmission "subharness" ...unless you have
a 5-speed V8 parts donor
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A LARGE hole is cut out of the
transmission tunnel
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Fabrication of structural patch to
said hole, and welding of patch and shifter pocket over hole... including
seam sealer and heat insulation (final steps shown below)

 
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In 4.2 cars, an additional modification is required
for the speedometer to read correctly
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Several modifications must be made to the cruise
control wiring
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Removal of instrument cluster to
eliminate the shifter display
General list of parts required:
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Clutch/brake pedal assembly from an
89-91 100/200
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Shifter "pocket" cut from said
100/200's transmission tunnel
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Shifter assembly
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016 transmission with 4.11 final
drive...V8, 5KQ, or 100Q
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V8 flywheel
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200Q or V8 clutch kit depending on
which transmission you use
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2 front CV axles
-
5-speed Quattroä
driveshaft
Other variations of this conversion
are listed on our Custom Conversion
Index. Cost:
Conversions can cost anywhere from
$3000.00 to $7000.00 depending on the type of modification and source of
parts.
More photos of the completed
conversion:

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The Master's Creation! Keith and his 4.2 V8 5-Speed
Conversion...
Read the happy customer's testimonial about our
5-Speed Conversion. |
| Comments from an envious
test-driver... I finally got
to drive Steve B's '93 with GermanAutoConnection's 5-speed conversion.
Cool, cool, cool. A couple observations: the obvious should be stated
first just for interest -- the car boogies! If I'm getting to 60 in just
under 7 seconds in my '91 3.6 5-speed, this thing's doing it in closer to
6, and is likely capable of mid-high 5's if beat on. This is because the
power comes on more quickly too -- mine's a crashing bore until 4k rpm...
Steve's starts pulling hard closer to 3k. I'd also "guess" he's hitting
100 when I'm hitting 90-95. Noticeable difference there. The manual box is
reportedly ~100 lbs lighter than the auto box too. That alone is a big
help.
The shifter snicks through the gears great, perhaps a bit more precise
than mine (granted the box has allegedly got 1/4 the miles mine does). The Boge shocks w/ stock springs and 255/17 tires are a nice set up too. I've
been kicking around a more stiff/lower setup for my stock suspension, but
now I'm not so sure.
What a clean OE-look the conversion is. Overall operation is seamless and
looks factory. The PRNDL display is unlit and off to the side (I thought
it would be vertical between the speedo and tach), and just looks like
unlit idiot lights.
Plus he keeps his cars x-tra clean and tight anyway. Steve runs a high-end
audio business so obviously the car's not lacking in that area. And the
'93s have some nice amenities like keyless entry and the updated CC system
that makes me envious. And considering what the 4.2 V8q shares garage
space with, it goes a long way that his passion lies with this one. Nice
car Steve!
-Dave C. |

More completed conversions. See more details on the Fun Page and our
Custom Conversion Index |
Custom
Conversions Index
Testimonials Page
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