Well - The car is running AND driving! I have put about 175mi on the car in the last 3-4 days, just driving around locally trying to get the clutch broken in and shake down the car before I make the long haul to Wookies. A couple things have shown up that I am in the process of addressing, but the major takeaway here is that this swap is indeed possible and there is now another manual 3.2 TT driving around the US.
Issue 1: My clock spring fell apart on me when I had my steering column off, I re-assembled it but I have a steering angle sensor code now. I cannot find anyone who has this in stock. So I have a ESP light on and a code stored for implausible signal. No driving consequence, just not ESP/Traction control for me
Issue 2: I bought a BNIB clutch switch for cruise control and to signal the ECU when clutch is/isn't depressed. After seeing a soft code in VCDS for no signal, and using the voltmeter on my switch, I determined I damaged mine by installing it incorrectly. These can only go one ONE WAY, and they self adjust/lock into place when they clip in. I was able to salvage a used one I had laying around and it fixed a rev hang issue I had when dis-engaging the clutch. Another new unit is on its way to me.
Issue 3: The BIG issue. Unrelated to the trans swap, but maybe timing - I am chasing either a timing fault, oil pressure issue, or a cam adjuster/phaser issue. The car gets to temp but then makes loud clacking noise around 80-85*C. The actuators are trying to reach their operating temp set point and it appears they aren't quite getting there. The noise has reduced as I have driven the car, and performed the output tests to fully actuate these phasers, but I have still had soft codes return and the occasional, albeit brief - valve train noise. I have ordered a set of new(used) adjusters, as well as new aftermarket VVT solenoids just to rule them out as culprits. I suppose. will also remove the cam bridge and double check that the filter screen is in good order. I was ALMOST THERE, but it appears I need to go back into the engine a bit to make some final adjustments on this car.
Driving Impressions: It is exactly what I wanted, and that's all that really matters right? The easiest way to describe the car now is that it feels like a MK4 .:R32. It essentially is now, but with a tighter chassis/body structure than its Golf cousin, and a different acoustic nature to it. The southbound clutch is fantastic, and the VF mounts, in conjunction with the 034 Dogbone I am running, the engagement and throttle response is INCREDIBLE. The DSG was definitely limiting this car's overall experience in some ways, and the most noticeable to me has been throttle response, and initial torque. I can lightly slip the clutch off the line and this car just puts you back. Before, with the dsg, this was always a lazy gesture. Same with kickdowns or hard hits to the throttle. While the VR6 always had great throttle repose as a motor, the drivetrain was always trying to play catch up, or limiting the connection by trying to predict what you wanted and when. The ergonomics of the manual shifter and pedals suit the cabin perfectly fine (like the TT225) and the car feels very natural as a manual. The car feels way less "loaded" in lighter throttle situations, and very manageable and easy to drive. Shifting into and out of corners now is a blast. I am, needless to say - thrilled with the results and would recommend anyone on the fence about this swap, to just do it. The DSG has its pros no doubt, but the driving engagement and joy of my setup now is a lot of fun.
