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Badger's Caddy Manual to DSG Build
Posted: Wed Jul 17, 2019 9:42 pm
by Badger89
Originally planning on keeping the Caddy standard for work purposes, slight change in circumstances mean I can modify it to work for me.
I drive many miles in stop start traffic so always preferred automatics (I have my motorbike for speed).
With a decent spec DSG Caddy Maxi costing a good £2k+ over a manual version - I decided I would build my own.
Having sourced a fully working donor (very very cheap) to get the parts I need and wiring, I'll be fitting all this into the Caddy once I have build what I need outside on the bench.
I got the Passat instead of the Touran based version due to the longer ratio, lower initial cost and access to wiring diagrams - these DQ250 DSG are also the updated mechatronic version and has been serviced regularly.
There are a few other parts to sort on this Caddy while I'm at it and will converting to ASZ while I'm there.
Done
Front Discs and Pads
FADR Stage 1 Remap
To Do
Lower Dog Bone Mount
6 Speed DSG Gearbox Conversion
Carpet Lining and Workshop
Cruise
Clocks
Seats
Re: Badger's Caddy Maxi Build
Posted: Mon Jul 22, 2019 4:26 pm
by Badger89
Re: Badger's Caddy Maxi Build
Posted: Sat Aug 03, 2019 9:44 pm
by Badger89
As this is going to be the new business van, I needed to clean it up, fit security locks and build the workshop to the rear, here is the start.
Next step is to finish off the locks and build the desk and storage followed by some drivetrain upgrades.
Re: Badger's Caddy Manual to DSG Build
Posted: Thu Aug 15, 2019 5:15 pm
by Badger89
Original post updated and finished installing the security locks and building the workshop in the rear.
Re: Badger's Caddy Manual to DSG Build
Posted: Sun Sep 08, 2019 9:53 pm
by Badger89
Re: Badger's Caddy Manual to DSG Build
Posted: Thu Sep 19, 2019 9:19 pm
by Darylg21
Keeping my eye on the one, looks very interesting. Will the drivshafts swap over onto the caddy? Or is there some CV changes to be had??
Re: Badger's Caddy Manual to DSG Build
Posted: Fri Sep 20, 2019 12:00 am
by Badger89
DSG Update
It's fitted! Well sort of...
I bought a DSG flywheel for the 1.9TDI engine as they are different to the 2.0TDI from the donor car.
The gearbox was lifted up from underneath and it required the passenger console / subframe to be unbolted and pulled away. It bolted to the engine perfectly fine and held in the van using the Passat gearbox mounts, starter and driveshafts.
Research showed that the 2.0TDI Passat Shafts are the same as the Touran / Caddy DSG driveshafts and bolt straight in with no modifications.
Just waiting for the DSG selctor to arrive as the Passat variant doesn't fit. These are the same as the Golfs / Leon but different to Touran / Caddy.
Next step is to sort the coolant piping and then attack the wiring
Re: Badger's Caddy Manual to DSG Build
Posted: Fri Sep 20, 2019 11:31 pm
by tommyzooom
Very interesting, and brave
Keep the pictures coming
Re: Badger's Caddy Manual to DSG Build
Posted: Sat Sep 21, 2019 7:08 pm
by Bamboo_Caddy
Wow, well done for taking this on. Will be sweet when its done
Re: Badger's Caddy Manual to DSG Build
Posted: Mon Sep 23, 2019 9:29 pm
by Badger89
Thank you, when complete I'll compile a guide
Re: Badger's Caddy Manual to DSG Build
Posted: Tue Oct 01, 2019 10:50 pm
by Badger89
Re: Badger's Caddy Manual to DSG Build
Posted: Wed Oct 02, 2019 9:04 am
by james400
Well do mate did you have to do anything regarding abs pump or ecu as the ecu is for a manual not auto?
Sent from my SM-G950F using Tapatalk
Re: Badger's Caddy Manual to DSG Build
Posted: Wed Oct 02, 2019 9:09 am
by Badger89
The ECU is the same on Caddy for both Manual and Automatic so it's simply a softcode change to say it's now automatic.
I do have a fault in the mechatronics unit for ABS however, that is due to the gearbox from the Passat expecting a different ABS controller than the Caddy. It still drives perfectly fine and changes gear as expected.
Looking at getting the gearbox refreshed to a Touran / Caddy firmware to see if that solves the issue.
Re: Badger's Caddy Manual to DSG Build
Posted: Sun Jun 28, 2020 9:56 pm
by Mtb993
Wow, amazing job, looks very OEM. bravo.
Re: Badger's Caddy Manual to DSG Build
Posted: Fri Feb 24, 2023 8:39 pm
by Cundyowl
This is cool as hell .
I’m really thinking of doing this to mine . I have a ASZ engine sat ready to go in maybe a dsg gearbox could make the difference . What’s involved with the wiring ?