VW T5.1 being upgraded to T6 4motion running gear

Yes quite confusing really as the only s/start flywheel changes are for the 6spd manual, this is at VW commercial too, hence them understanding me 100% but not being able to give me a solid part number to use..
So I am going to go with this variation above, if it's good I wont need to swap out clutches .... o_O
 
Rear engine support bracket arrived today, came from a 2017 4motion, CAA engine code ...??
Part no:7E0199370A .... horrified initially as it was miles away from what I had removed in length, mounting positions changed etc,
Fortunately VW used the same cylinder block castings, so when offered up to the block, it mounts on different perches on the back of the block and lines up spot on,
it also has the side mounts to attach the bevel box support bracket onto.
I also got the 1" long gearbox dowels today, ordered them at 8.30am, they were delivered from heathrow and sitting in maidenhead commercials by 10.30am .. wow...
So I mounted the spacer plate between the box and block and I can locate the box correctly on the dowels... certainly no place to cut corners...
Im waiting for the DMF to be delivered, hopefully this will be correct,
I will have to fabricate the dpf mounts, top and bottom, if I had the round dpf I would just go factory mounts, I need to get the bevel box in to see how close the dpf is, may still need round one ... or delete pipe ..... but moving forward okay

 
Still waiting for DmF…
I cut off the lower dpf mount from the old rear engine support bracket, then tig’d it to the 4motion bracket, it came out alright.. hopefully that’ll work for lower dpf support, I have an idea for the top mount but struggling til I get it slotted together..

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So moved along a bit…
correct dmf ordered and now fitted.
I got gearbox, bevel box in, waited for rear engine mount, arrived within 24hrs, not like idiots taking 5days to ship the dmf out the door….3days later that arrived….
So all buttoned up except for the turbo to dpf and the dpf …
Anyone have a 4motion dpf for me ..??
I made up some subframe locators this morning on lathe, crudely used some wheel nuts opened out then trimmed the cone off, they fit snug inside bushes and pull the ahoulder inside the bush inner collar up, used 3 old bolts, tig/brazed them, absolutely spanked it at locating the subframe … anyone needs them let me know…
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I managed to get a scan off the T6 dq500 dsg box fitted into my t5 tonight …
Now bare in mind that even the vw master tech could not answer my questions as if this dsg swap is plausible … he even said he would not think it would work as there are different temperature sensors..
So I checked the gearbox wiring diagrams with massive help from @Pauly … thanks for those current flows bud
I concluded that the wiring is in the loom and module not the gearbox, as they use same pins…
I can’t start my van so I opted for second best…. beer and curiosity got better of me..
I connected battery and laptop, scanned my ecu…. check out the 2 scans, 1) is my old T5 gearbox additional info
Address 02: Auto Trans
Control Module Part Number: 0BT 300 045 R
Component and/or Version: DSG DQ500-7F H08 2241
Software Coding: 0014
Work Shop Code: WSC 00000
VCID: 4487F917CF9BD6ABA7-8010

Advanced Identification/FAZIT
Identification: SME-RBG
Revision: 00H08V01
Date: 30.04.15
Manufacturer number: 0413
Test stand number: 0451
Flash Status
Programming Attempts(application): 0/1/1
Successful Attempts(application): 0/1/1
Programming Status: 00000000
Flash Date: 00.00.00
Misc.
Hardware number: 0BH 927 711 C
Workshop System Name: J743
ASAM Dataset: EV_TCMDQ500021
ASAM Dataset Revision: 001001
VCDS Info:
VCID: 4487F917CF9BD6ABA7-8010
Labels: 0BH-927-711.clb
ROD: EV_TCMDQ500021_VN75.rod

2) is the T6 gearbox… additional info
--------------------------------------------------------------------------------


Address 02: Auto Trans
Control Module Part Number: 0BT 300 012 C
Component and/or Version: DSG DQ500-7A H11 5302
Software Coding: 0014
Work Shop Code: WSC 00000
VCID: 2F6DA6BB761D45F36A-807A

Advanced Identification/FAZIT
Identification: SME-RBG
Revision: 00H11V01
Date: 13.10.17
Manufacturer number: 0413
Test stand number: 0338
Flash Status
Programming Attempts(application): 0/1/1
Successful Attempts(application): 0/1/1
Programming Status: 00000000
Flash Date: 00.00.00
Misc.
Hardware number: 0BH 927 711 G
Workshop System Name: J743
ASAM Dataset: EV_TCMDQ500021
ASAM Dataset Revision: 001001
VCDS Info:
VCID: 2F6DA6BB761D45F36A-807A
Labels: 0BH-927-711.CLB
ROD: EV_TCMDQ500021_VN75.rod


Note just a few rev. changes, but rest is all good.
Looking forward to resetting the dsg when I get the turbo to dpf pipe fitted, or I "trim" mine to fit ....
 
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ps i have already looked for that part and currently drawing a blank, can find the propshaft (or cartenshaft as VW call it) but not that carrier bit, let me know if you get stuck ands i will revisit it :)
 
ps i have already looked for that part and currently drawing a blank, can find the propshaft (or cartenshaft as VW call it) but not that carrier bit, let me know if you get stuck ands i will revisit it :)
Wow .... I wrote in my reply to you about that(prop centre mount stand off bracket), but hit backspace, took it out, then posted it, as I asked yeha on his ... strange ....
Well I don't care for that bracket if I don't need too.... I did think the prop would be a bit close to underside, before I had seen yeha's picture earlier,
so now I think I need to see a picture of a T6 SWB 4motion prop .... around about where the carrier bracket attaches .... I asked cordwalliss commercials if I could have a peek under one, but no 4motions available or in for service ....
 
Both prop mounting areas are there on my chassis and the holes are open on the heatshield. If I haven't got a photo already, I'll get one.
 
Both prop mounting areas are there on my chassis and the holes are open on the heatshield. If I haven't got a photo already, I'll get one.
You have a lwb then..?
I only have one carrier bearing…
I can’t say I look at lwb stuff as that isn’t needed…
My carrier location has 2x 13mm bolts holding the heat shield in place.
Bit more concerned on front end as I gotta buy a turbo cat back and dpf now…£££ …. my monstrosity will not fit without cutting the hell out of it, then there is such a weight with it still, I will spend a day supporting it up correctly ….
So I need the proper set up … visually… coz I’ll empty it out no doubt …
 
So unsurprisingly my original 2wd turbo cat back dpf unit will not fit between bulkhead with 4mo bevel box installed..... I had to try it....
So I have ordered a turbo cat back for a 4mo CAAC engine, mounting brackets off the bevel box, this is Euro5 spec, so just has a lambda sensor pre cat bung... no other bungs or sensor ports.

I cannot find a Euro5 DPF for love nor money .... all I can find are turbo cat backs and dpf's with this adblue crap sensors etc.... yeah chop that out of course ... but ......
these dpf's are second in exhaust line, they have the pressure differential sensor pipes split over the first unit(turbo cat back) and second pipe from that unit is right at the back of the DPF(as expected)
Now my (ordered) euro5 turbo cat back has no placement for any pressure diff. sensors and I am thinking that this unit will not work if I get a rear DPF section with just the post flow bung..?? It's a simple self explanatory answer I think, simply coz I am missing my dpf pre-flow sensor ..... that wont just work, plug n play..
Now do I ....
1)Cut the pre flow bung out my old dpf and transplant it to the T6 Dpf to make fit .....??? (maybe not enough tank at top of dpf unit to read flow if welded in..?)
2)Do I delete the emmissions and go finger up to vosa.... (a)drag pipe from turbo or (b) just the turbo cat back & no dpf (i like this 2nd choice)
3)Spend lots and lots of pennies I dont have for 100% correct system... like oem full cat & dpf

Remap is on cards if I dpf delete..
All thoughts are well recieved so lets have some please ..... I'm drowing in choice ...... thanks all
 
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So I’m all done on the fwd section except turbo cat back and dpf,
fully serviced, engine and gearbox oil and filters done, I squeezed in 5.5litres into the box, I didn’t read up whether the mechatronics drain fully, but the box has been sitting off a vehicle for some time, it was a little golden, was no point putting new oil on old as I had the service kit, I can get the back jacked up now as on ramps on wheels too …
I need to get this running as my dd…
 
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Great project. It's something I would like to do one day when I've finished all my other ones. I think I would go for a 6speed manual.

Please post some photos which will help others in the future.
 
Great project. It's something I would like to do one day when I've finished all my other ones. I think I would go for a 6speed manual.

Please post some photos which will help others in the future.
Thanks .... well I will do my best, but the gearbox transplant is the same as factory, so no difference from the workshop manual.
No corners cut as everything has been factory produced, just a case of finding the right bits, as the info from what it exactly came from, vin even engine model was unknown, so a few hurdles along the way.

So got the back up now on axle stands too, dropped h/brake cable, cleaned waxol from chassis and will get the old h/brake brackets out the way, I am looking for the haldex subframe position, no dimples or pre-drilled holes on cross bracing, but I just found some pics on haldex subrame location, it doesn't sit in the centre of the rear brace, but almost overhangs the brace with the large bonded mounts, so located off centre of brace to the rear, front haldex mount i am unsure.

I also need to collect the exhaust system, cat, dpf even bit over rear axle, from the same vehicle the transmission and running gear came from ... just found out I can have them,
so it's euro6 cat/dpf .... no blue rinse though, so I will just block those bungs off, another trip to middle england again... unless anyone has a courier running midland to south east ...??
 
Just got one h/b/cable mount off… looks good underneath…
1x front Haldex subframe location already underneath it….. @yeha you'll be pleased mate….

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Been tough going .. I lost my mum thursday …
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Waiting on new cables & brackets
Cat dpf & exhaust bits, underneath almost done
I tigd the nuts in, shit job on yr back with burning waxol running down yr fingers ..
 
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Commiserations.
Cracking photo's and I'm glad at least one hole is there. I'll put a bit more effort into mine.
 
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