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Old March 22nd, 2017, 11:47 PM   #1
Whitbread
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Default TDI Ranger swap

Howdy folks! I needed a 4wd replacement for my mechanical tdi swapped VW Rabbit pickup, so after some hunting I found a 2000 Black B3000 5 spd 4x4 down in San Antonio TX for a good deal. Got lucky that I had a friend down there for work and he was able to pick the truck up on Thursday and drive it back to Louisville KY. I drove down over the weekend and brought it back to my mad scientist lab in the woods of northern MI. Turns out, the 3.0 has a blown head gasket as it took 3 gallons of coolant to get from KY to MI. No idea how it made it from TX to KY being 2 gallons low and didn't blow up. Oh well, I didn't buy it for the turd v6 anyway. But due to that, my time table is getting moved up and this thing is getting swapped ASAP as I'm not going to do a head gasket on the 3.slow.


About 4 weeks ago I yanked a fully dressed 2004 Passat TDI engine/harness/ecu from a u-pull yard in the ghetto of detroit for $412.50. Sold the trans computer and intercooler off for $425, so the motor didn't cost me a dime. It needs a cam as 04-06 TDI's do, but I'm a dealer for Colt Cams so that's an easy fix. I'll also delete the balance shaft and put a fresh timing belt on it. I'm hoping all the vw accessories will clear and save any custom belt/pulley work. It's going to get a small set of K03/hx30w compounds which should be good for 180whp/350wtq with the stock injectors. When I upgrade them down the road, 220whp/425wtq should be doable from the same turbos.



Put the truck to work and went out and cleaned up a few dead limbs that came down in the wind storm last week. It's already sagging 1.5" with just this load so I ordered the airlift helper bag kit, firestone pump, and assorted fittings to hook it all up. I have a 20ft aluminum car hauler I plan on towing with VW's on it and I know that will squat it more than this.



After unloading the bed, I put it on the hoist to get a look at the underside. Holy crap! I'm so jealous of guys down south/out west. I can't believe this is a 17 year old truck with 216K on it. Looks like a 2 year/20k old truck from up here. This will get the most overkill undercoating job ever done when I get done with the swap and will be washed inside every time it has to see salt.








Worst rust I can find on this thing LOL.



From my googling, this is a very common issue. Hopped on ebay and ordered the aluminum repair ends for $14 and a new pair of Depo door handles as they were only $12/each.








Helper bags to prevent saggy ass syndrome







I freed up an engine stand and started on the TDI. Pulled the trashed cam to install some head studs and stiffer valve springs. I'm planning on 45-50psi of boost so I'm setting the engine up accordingly.


This evening I rolled the engine over to work on the bottom end. Balance shaft setup was deleted and stronger main bolts installed.

Before


After


All sealed back up.


Electric shift T case isn't reliable shifting in/out of 4wd so I hunted down a 2003 manual shift 1354. Got it to my door for $150 from a wrecking yard in Wisconsin. Now I just need to find the shift linkage and floor plate.



The 7.5" rear end has a TON of backlash, so I hunted down a 8.8" from a fx4 with a limited slip and matching 4.10 gears. Hopefully picking it up this weekend!

If all stays on schedule, I should have the custom adapter kit in 3-4 weeks and I can get swapping

Last edited by Whitbread; March 23rd, 2017 at 12:28 AM.
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Old March 23rd, 2017, 12:06 AM   #2
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Interesting. If I was on Ranger-forums .com I would have said post there, those guys love this sort of thing. Even if it is a bastard child of ww2.


I'll be following your build, it looks like it'll be a fun ride.
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Old March 23rd, 2017, 08:30 AM   #3
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Cool build
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Old March 23rd, 2017, 10:16 AM   #4
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Cool build. Very curious to see how it turns out and what kind of mileage you can get out of a truck like this........
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Old March 23rd, 2017, 11:33 AM   #5
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Nice deal you got going on.
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Old March 23rd, 2017, 04:12 PM   #6
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interesting build!
clean little truck!

i want a standard cab, long bed, 3.0, 5 spd, 4x4 ranger to haul one snowmobile cheaply.
most are just too rusty to dick with up here.

was there ever a 4 cylinder 4x4 ranger?
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Old March 23rd, 2017, 05:00 PM   #7
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Default 4 banger 4x4 ranger

They made the 4cly 4x4 rangers for a few years... buddy had one in college and it was a slug but, did good on trails and in deep Vermont snow! Hauled fire wood like a champ!

COOL TDI BUILD!
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Old March 23rd, 2017, 07:42 PM   #8
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Quote:
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most are just too rusty to dick with up here.
Aaaaand that's why I bought this from San Antonio . I looked at 2 up here and they were rusted to hell.


Fuck this pos that doesn't ever want to shift when I actually need 4wd.


Manual case in


Starting to pull rear axle down. Going to Gene's auto in TC tomorrow to grab the transfer case shift linkage and an 8.8 with correct 4.10's and a posi from an FX4 ranger they have there.
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Old March 23rd, 2017, 11:17 PM   #9
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First time I've dropped an axle from a 17 year old truck where no torch was needed



Bad part is that I now find this truck has 3.73s reading the axle tag. I was 99% sure it had 4.10's as I ran the math on mph/rpm/tire size/trans ratio. So apparently either the speedo or tach is rather off. Since my rear end is a time bomb regardless, the question is; do go the cheap route for the moment and get a 3.73 8.8" and put a lock right in it down the road? Or buy a 4.10 8.8" that has a factory limited slip and a 4.10 front end to match? By the time I buy the lock right, I'm at the same cost in the end, which is more than I was planning on spending tomorrow LOL. No matter what I need to go to Gene's for the t case shift linkage and floorplate, so I figure I'll bring my rear end and try to talk deal in person.

Since I'm building this truck for towing/hauling, I know the 4.10s will make more sense in the long run and with 31's will put me at 2632rpm@75mph in 5th. That's perfect for the tdi empty cruising and 3krpm @68mph in 4th for any grades with car on a trailer. Decisions, decisions.....
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Old March 24th, 2017, 12:03 AM   #10
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My 08 had 3.73's, a manual trans and 265/75r16's. It didn't bother me. I didn't tow too much with it but the few times I did (once from Detroit to SL and back) I had no problems. I never came close to my towing max and I left it in 4th for part of that SL trip. Mine also had a 4.0L so power was 208hp and 238ft/lbs


I would keep the 3.73's. Keep in mind when you order the locker or limited slip that the 8.8 came with two different splines. A 28 spline (what I had with factory ls) and a 31 spline.

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Old March 24th, 2017, 08:09 AM   #11
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Awesome!
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Old March 24th, 2017, 08:40 AM   #12
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with the added torque from the tdi, I would stick with the 3.73s. I ran 3.54s in my old 12v cummins. Guess it really depends on end tire size as well...


Any reason why you went the VW route over say the Kubota 2.2?
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Old March 24th, 2017, 03:51 PM   #13
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That was a lovely trip to Gene's. Guy on phone claimed up and down they had a manual t case 4.0L ranger out in the yard that I needed the shift linkage from. Turns out it was an electric shift manual trans truck . Now rather pissed I just drove 1.25 hours each way for nothing, we talked on some axles. They didn't have a 4.10 front to go with a 4.10 posi rear, so we settled on a 3.73 8.8" rear end for $170. Even got them to pressure wash it for me! It's only the 28 spline, but I'm sure it will be fine for my uses. I'll put a locker of some kind in it later. Going to hit it with wire wheel, paint, new seals, and transfer all my good brake hardware over.




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Any reason why you went the VW route over say the Kubota 2.2?
Because I'm a distributor for an adapter kit company that has the engine mounts and adapter kit for the vw, I work on tdi's and other European diesels for a living, and mostly because I can get 220whp/450wtq out of that little 2.0L if I want to try and break ranger parts .
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Old March 24th, 2017, 03:55 PM   #14
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Quote:
Originally Posted by Whitbread View Post
That was a lovely trip to Gene's. Guy on phone claimed up and down they had a manual t case 4.0L ranger out in the yard that I needed the shift linkage from. Turns out it was an electric shift manual trans truck . Now rather pissed I just drove 1.25 hours each way for nothing, we talked on some axles. They didn't have a 4.10 front to go with a 4.10 posi rear, so we settled on a 3.73 8.8" rear end for $170. Even got them to pressure wash it for me! It's only the 28 spline, but I'm sure it will be fine for my uses. I'll put a locker of some kind in it later. Going to hit it with wire wheel, paint, new seals, and transfer all my good brake hardware over.




Because I'm a distributor for an adapter kit company that has the engine mounts and adapter kit for the vw, I work on tdi's and other European diesels for a living, and mostly because I can get 220whp/450wtq out of that little 2.0L if I want to try and break ranger parts .


Ah.


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Old March 24th, 2017, 06:17 PM   #15
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After wire some wheeling and brush on rustoleum, the pig now has some lipstick!

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Old March 25th, 2017, 01:46 AM   #16
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You should be fine with that 28 spline. They're both strong.
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Old March 25th, 2017, 12:43 PM   #17
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You should be fine with that 28 spline. They're both strong.
Good to hear. It will never see larger than 31s or crazy wheeling. Mostly hauling loads of wood and dragging around broken vw's .

Got the axle in the morning. Test drive was great; no more clack-clack-clack between shifts in the lower gears .
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Old March 27th, 2017, 01:38 PM   #18
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Houston, we have boost.
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Old April 6th, 2017, 09:44 AM   #19
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LUK 93-96 Ranger 4.0L flywheel for $34 from rock auto


Made a viscous fan delete pulley hub




Got the clutch yesterday too!


Got the adapter made to bolt the hp turbine housing to the exhaust manifold.



Last edited by Whitbread; April 6th, 2017 at 11:40 AM.
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Old April 6th, 2017, 06:11 PM   #20
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I've got a locker and carrier you can throw in that axle
But its 30 spline.
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