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Ben's '94 Cabriolet build

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 Post subject: Re: Audi Cabriolet Project - time for a manual swap?
PostPosted: Sat Oct 15, 2011 5:13 am 
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mach 2 with my hair on fire
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Location: Cincinnati, Ohio
ChrisAudi80 wrote:
I'll read any thread involving use of the 12v V6. Cool you are doing the port matching work. Are going to open the IM and clean/port that, too?


I probably will eventually. For now I wanted to do the work on the heads and get the car running. I have a spare IM now so I can port that at my leisure. It's so much easier to change that out than the heads.

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


Last edited by grillage on Sat Sep 22, 2012 7:32 pm, edited 1 time in total.

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 Post subject: Re: Audi Cabriolet Project
PostPosted: Sat Oct 15, 2011 5:35 pm 
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mach 2 with my hair on fire
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Location: Cincinnati, Ohio
Lots of progress today...
Got the old engine out and the new block in.

Image
Image

Found more damage in the old motor. The thrust bearing at the rear of the engine was toast...
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Image

You can see all the shavings in the oil pans...
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All that's left is to put the heads back on and put it all back together. Hopefully I'll be done in time for a drive!

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1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet Project
PostPosted: Sat Oct 22, 2011 12:39 pm 
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mach 2 with my hair on fire
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Location: Cincinnati, Ohio
I got everything back together last Monday and I was delighted that it started! I drove it all last week and put about 100 miles on the new engine.

A couple tweaks and mistakes I made were made clear...

I had a CEL flash a couple times for a second or two at a time. I had forgotten to connect the DS O2 sensor.

I had a horrible burning rubber smell coming from under the hood. I hadn't reconnected the vac hose from the firewall to the cruise control. It was resting on the DS exhaust manifold and was about an inch shorter than it used to be. Duh!

Lastly, the TB was on too tight causing a whirring sound that was a little alarming. I took the belt back off This morning and fixed it. I had a hell of a time breaking the sprockets free but it's kinda useless to change the tension without breaking them free.

I put 8 oz of Marvel Mystery oil in the crankcase and a bottle of Seafoam in the gas tank today to help clean out the engine.

The only mystery that remains is that the odometer/speedometer cut out sometimes. At least twice they've stopped working while I was driving. I would think it has to do with the sensor on the drive plate - it may be bad or it may be installed just barely off. Or could be not plugged in right.

All in all I have to say I love the car. I just took a ride from Cincinnati into Kentucky and back across the river down a very scenic route. With the wind deflector installed there is very little noise and the wind is not bad at all.

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Ben's Audi Cabriolet Project- about to do a manual swap!
PostPosted: Sat Sep 22, 2012 7:26 pm 
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mach 2 with my hair on fire
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Well, the car served me well all year until about 3 weeks ago. The transmission started behaving strangely - shifting weird, taking a while to get into gears and then all hell broke loose. It felt like it was in more than one gear at a time. Bogging the engine down badly too. All with no codes from the TCU
I tried a fluid swap to no avail and took it to AAmco the other day for a free diagnosis. They confirmed my suspicions. More than one set of hydraulics was trying to engage at the same time.

So I need to decide whether to find a junk yard auto trans and hope that it will somehow last forever (the failed one is its third) or bite the bullet and swap in a manual. The biggest obstacle for the manual is that my wife won't be able to drive it and she wants me to sell it once its fixed. That's not going to happen. As far as I'm concerned, any car that I replace an engine and transmission in will be mine forever.

So, I know that this has been done and have a pretty good idea of what I need from a 93-95 FWD 90:

Transmission
Mounts
Master, slave and hose
Shifter
Shifter linkage
Front axles
Pedal assy

I have read that I need the center console too but can't figure out why I would

Anyone out there have some good BTDT advise or happen to have any or all of the above list near Cincinnati?

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet Project - Manual swap and an AEB?
PostPosted: Sat Sep 29, 2012 6:12 am 
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mach 2 with my hair on fire
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As I wait to get all the Trans parts, I have been thinking about an AEB swap at the same time.

Am I correct that both AEB's and the 012 FWD transmission can be sourced from Audi and VW too?

Anyone happen to know if this is as simple as finding the right motor mounts (I searched and found that already) and everything should bolt right in?

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet Project - Manual swap and an AEB?
PostPosted: Sat Sep 29, 2012 4:39 pm 
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kickin' tires'n lightin fires

Joined: Sat Jan 24, 2009 10:39 am
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Location: Rhode Island (not an actual island)
The Cabrios came with 1.8 in Europe so your best bet to get mounts is there. the 90 transmission mounts bolt to the A4 or Passat Transmission


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 Post subject: Re: Audi Cabriolet Project - Manual swap and an AEB?
PostPosted: Sun Sep 30, 2012 3:12 am 
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grillage wrote:
As I wait to get all the Trans parts, I have been thinking about an AEB swap at the same time.

Am I correct that both AEB's and the 012 FWD transmission can be sourced from Audi and VW too?

Anyone happen to know if this is as simple as finding the right motor mounts (I searched and found that already) and everything should bolt right in?


Yes and yes.
You can also check out this thread on the Kotex: http://forums.vwvortex.com/showthread.php?1774571

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96 Audi S6 20vt sedan auto, PRJ chipped.
95 Audi 80 converted to Quattro + AEB.


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 Post subject: Re: Audi Cabriolet Project - Manual swap - it's on!
PostPosted: Wed Dec 12, 2012 6:07 pm 
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mach 2 with my hair on fire
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This stuff arrived today....
Image
Thanks barfbasket!

Now I need the transmission and I'm off!

I have a 99 passat 1.8T transmission with 61k miles near me that ill be getting shortly...

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet Project - Manual swap - it's on!
PostPosted: Wed Dec 12, 2012 6:49 pm 
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kickin' tires'n lightin fires

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grillage wrote:

I have a 99 passat 1.8T transmission with 61k miles near me that ill be getting shortly...


V6= better


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 Post subject: Re: Audi Cabriolet Project - Manual swap - it's on!
PostPosted: Wed Dec 12, 2012 7:15 pm 
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mach 2 with my hair on fire
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See the last post of this thread....
https://www.motorgeek.com/viewtopic.php?f=15&t=49132

The gearing is the same except 2nd gear which seems like a better gearing than a b4 v6 trans. The b5 v6 transmissions have a different gearing than the b4s. What do you think?

The 1.8t is $250 and local to me. Seems like a good deal. Though with my luck as soon as I buy it a 50k mile b4 non Quattro manual audi 90 will show up at my local Upullandpay.

_________________
CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet Project - New Years resolution!
PostPosted: Mon Dec 31, 2012 8:54 pm 
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mach 2 with my hair on fire
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I will fix this at in 2013! All I need is the transmission and a warm dry place to work. The rest of the parts are here!
And my solid 034 short shift kit will be here in a couple days.

_________________
CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - transmission swap questions
PostPosted: Sat Jan 05, 2013 2:31 pm 
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mach 2 with my hair on fire
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Location: Cincinnati, Ohio
It's on.

I picked up this CAC code 012 Transmission from a 1993 90S with 53,000 miles today.
Image
Image
Image

I still need a Flywheel but I have a line on a lightweight Aluminum version and on an OEM version as well.

I need advise on the "new" transmission as far as what I should do before the install. What other than the Clutch and Flywheel should I be doing to this? What is the recommended trans fluid?

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - transmission swap Progress!
PostPosted: Sun Jan 06, 2013 4:04 pm 
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mach 2 with my hair on fire
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Posts: 1339
Location: Cincinnati, Ohio
I started digging in today and made some progress on the disassembly.
Before...
Image
Got the TCU disconnected and removed...
Image
Disconnected the Steering Column and removed the rear section of it...
Image
Image
Removed the auto Shifter and took out the center console
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When I did the Clutch Master Cylinder on my old Audi 90 I had a hell of a time getting the hydraulic lines detached from the MC and then reattached. I ended up taking out the Brake Vacuum Booster and it revealed the back side of everything. With that in mind I did that here too.
I had to take the front two ABS lines off to get it out and I'll have to bleed the brakes when I'm done but I would likely do that anyway since I am adding the clutch into the hydraulic system of the car.
I think I'll appreciate the top view of the transmission once I get into the replacement too...
Image

Now with that out and the pedal assembly removed, I have a lot of room underneath...
Image
Image
I replaced the O-rings in the cruise control vac switches on the "new" brake/clutch assembly while I had it on the workbench. Also got the MC installed

They appear to be the same assembly although I have always read I needed a manual specific one.
Image

I just placed orders for everything else I need. All the seals I could find on the drawings from ETKA and the Bentley, new bolts for the flywheel and the transmission housing (they're different Auto to Manual) and the clutch Kit. I'm sure I'll find stuff I am missing as I go but I have plenty of time.

The next steps are to jack it up and actually remove the old transmission. then start putting everything back together.

if anyone has any BTDT advise on what I should do to the transmission itself before install I'd appreciate it.

_________________
CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - transmission swap Progress!
PostPosted: Sun Jan 06, 2013 5:41 pm 
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Nice project... Audi 90 Cab's are very nice cars... save for the slushbox. They seem to sell very cheap if engine or trans are bad.

I have been enjoying the stock AAH in my 94-90Q...

Always thought a 1.8t 5 speed fwd swap would make a really nice cruiser if you can get the "victim" and donor @ good prices... so long as you have a Quattro for the snow.

_________________
1987 elQUANTUMino Project
1990 Pearl Coupe Quattro - Cone Killer SOLD
1994 Silver 90Q "Freeda" Snow Beater now RXer
1992 Blue Eurovan "5+5" "DasFeld"
1992 Forest Green Cabriolet Project Gone
1988 Red MR2 Supercharged
Future? 1986 AE86 Coupe 1985 GTI
Wife's Ride 2002 Saab 9-5 "Baab the Saab"
Parting 1993 90q 1996 A6Q Avant Gone


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 Post subject: Re: Audi Cabriolet - transmission swap Progress!
PostPosted: Mon Jan 07, 2013 8:14 pm 
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mach 2 with my hair on fire
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Yeah, I agree a 1.8T would be a great next step for this car. I haven't ever done a transmission swap or even just a clutch job so I'm taking it one step at a time.

The Cab is a great warm weather car - especially with the S6 for winter.

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - transmission swap Progress!
PostPosted: Tue Jan 08, 2013 3:22 pm 
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I just did my first clutch (almost solo)... I have watched others do them before and helped. I just needed some assistance with the final wrestling in/out... had a friend who is expert Subaru wrench who helped with final assembly/install just to be sure. One less driveshaft if you are doing FWD!

_________________
1987 elQUANTUMino Project
1990 Pearl Coupe Quattro - Cone Killer SOLD
1994 Silver 90Q "Freeda" Snow Beater now RXer
1992 Blue Eurovan "5+5" "DasFeld"
1992 Forest Green Cabriolet Project Gone
1988 Red MR2 Supercharged
Future? 1986 AE86 Coupe 1985 GTI
Wife's Ride 2002 Saab 9-5 "Baab the Saab"
Parting 1993 90q 1996 A6Q Avant Gone


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 Post subject: Re: Audi Cabriolet - short shifter questions
PostPosted: Tue Jan 08, 2013 8:03 pm 
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mach 2 with my hair on fire
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Happy birthday to me! The short throw kit from 034/JHM came today. I have an 034 kit on my S6 and wanted this for the cabriolet.
Image
Image
How much grease (and what sort) should go inside the boot here?

Also, the linkage itself, is there any adjustment or replacement for the bushing here?
Image

Oh yeah, also how is this adjustable?

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - short shifter questions
PostPosted: Tue Jan 08, 2013 8:16 pm 
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No grease in the boot. See this for the linkage rebuild
http://forums.audiworld.com/showthread.php?p=18597498
EFI express also sells a solid linkage bushing upgrade.

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90 90Q 20v 91 200 20v avant 03 S6 avant


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 Post subject: Re: Audi Cabriolet - short shifter questions
PostPosted: Sat Jan 19, 2013 2:11 pm 
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mach 2 with my hair on fire
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yodasfro wrote:
No grease in the boot. See this for the linkage rebuild
http://forums.audiworld.com/showthread.php?p=18597498" onclick="window.open(this.href);return false;
EFI express also sells a solid linkage bushing upgrade.

This was super helpful. Thanks!

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - auto trans is out!
PostPosted: Sat Jan 19, 2013 2:26 pm 
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Location: Cincinnati, Ohio
It's out!
Image
I was able to get the auto trans out today after quite a bit of work.
Image
Now I realize that I need both mounting brackets
8A0399114
8A0399113B

The ones from the auto are clearly different. Anyone happen to have these lying around?

I got the u joint refreshed thanks to yodasfro and the above link, and all the cv boots replaced and repacked.

The clutch kit showed up this week and I ended up finding a new audi oem dual mass flywheel on Craigslist for $100

Here's what is going back in:
Image

Image

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - auto trans is out!
PostPosted: Sun Jan 20, 2013 3:07 pm 
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mach 2 with my hair on fire
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Location: Cincinnati, Ohio
Spent today removing the flex plate and the bushing in the end of the crankshaft. Has anyone done this who can confirm that I don't need to remove any more of the bushing?

Image
Image
Image
Image

Do I need to remove the part that is inside the crankshaft?

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - auto trans is out!
PostPosted: Sun Jan 20, 2013 5:55 pm 
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kickin' tires'n lightin fires

Joined: Sat Jan 24, 2009 10:39 am
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Yes.... pack it with grease find a rod as big as that center hole and hit it with a sledge hammer. the grease will push that piece out.


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 Post subject: Re: Audi Cabriolet - auto trans is out!
PostPosted: Tue Jan 22, 2013 3:02 pm 
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Great project and documentation! Always nice to actually see what's going on with someone's build.

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|| 2010 Golf Sportwagen TDI /// #farmenwagen
|| 2002 Dodge Ram 2500 24v Cummins 4x4 #bertancummins
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 Post subject: Re: Audi Cabriolet - auto trans is out!
PostPosted: Tue Jan 22, 2013 7:23 pm 
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mach 2 with my hair on fire
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Thanks, I know that the cabrio isn't exactly everyone's favorite car here on account of the 2WD but it's a fun project!

I'm glad someone's reading!

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CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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 Post subject: Re: Audi Cabriolet - auto trans is out!
PostPosted: Sat Feb 09, 2013 5:21 pm 
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mach 2 with my hair on fire
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Joined: Wed May 25, 2011 7:56 am
Posts: 1339
Location: Cincinnati, Ohio
Made some progress today...

The new pedal cluster is in, as is the clutch MC and 034 short shift kit
Image
I learned a couple years ago that the easiest way to get to the lunch MC is to take out the brake booster. It's now back in too.

Got the right grommet for the firewall and put the wires from the outside temp sensor through it too...
Image
Image


Also got rid of the lock cable tha makes you be in "Park" before you can take the key out...
This side is attached to the shift lever on the auto
Image

The other end attaches right above the ignition switch (seen here from an angle only an iPhone can see)
Image
The top pops off...
Image
To reveal this...
Image
Which pops straight up once the clips are taken off.

Now the key comes right out!

All I need now is the last mounting bracket for the transmission and I can everything else back together. Stay tuned!

_________________
CURRENT
1995 90Q 20VT
- 1987 Porsche 924S - 1979 Porsche 928

PAST
1994 Cabriolet - 5 speed - 1986 Audi Coupe GT - 1993 Audi 90 CS Quattro - 1990 CQ - V8 - 1995.5 Audi S6 - 1993 Audi V8 - 2013 A5 Prestige - 2011 A4 Avant


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