Wohoo! The elusive fx4 manual transfer case shift linkage/floor plate/boots showed up! No more crawling under the truck to engage 4wd LOL.
TDI Ranger swap
19
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 :bdr2:
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 :bdr2:
21 - 40 of 70 Posts
4
Yes, I'm using the ranger trans to make the swap as simple as possible. Absolute cheapest way to bolt a tdi to a rwd trans is http://tditoyota.com/products/tdi-engine-adapter-plate-for-toyota-22r-bell-housing . I don't know squat about 4 cylinder yota tranmissions as to how much TQ they'll handle so I can't offer a comment there.
Got the shifter bits installed!
The unobtanium fx4 floor plate
Had to make a custom bolt thingy, bushings, and sleeve as I didn't get them with the shift linkage. Made the center pivot bushing sleeve .020" taller than the delrin bushing so everything would pivot freely.
Glued the fx4 bezel back together and whipped up an aluminum piece to cover the carpet mismatch. I think it'll work good enough for a work truck!
2
It's getting there! Killing time till adapter kit gets here :rock:.
Got the $58 ebay snorkel installed while I had a quick opening in the shop today. Fits as well as I could hope for a Chinese land cruiser snorkel on a ranger :sonicjay:.
I'm not bothering to hook it up yet, just doing the crap work in prep for the swap. I'm trying to find a metal canister style air filter from an old gen set/hilo/bobcat. It will be easier to work with for I'm what doing over the stock Ford airbox.
2
Wohoo! My adapter kit finally came in! Time to get back rolling on this project!!!!!
Since these last pics I added a overpacked ford clutched limited slip, and a gt500 finned rear cover because it was cheap on ebay.
TD Conversions adapter kit
Also scored a set of cheap 16's from a newer fx4 ranger so I can run some e range 265/75-16's and not be worried about sidewalls blowing out with a bedload of wood.
Plan is to yank the pos 3.slow out on sunday!
Since these last pics I added a overpacked ford clutched limited slip, and a gt500 finned rear cover because it was cheap on ebay.
TD Conversions adapter kit
Also scored a set of cheap 16's from a newer fx4 ranger so I can run some e range 265/75-16's and not be worried about sidewalls blowing out with a bedload of wood.
Plan is to yank the pos 3.slow out on sunday!
12
Lots of progress now!
Since you have to drop the front diff to get to the driver side motor mount bolt anyway, figured it was a good time to clean up the 4.10 junkyard front end and put it in.
The adapter kit is set up to use a 4.0L clutch, flywheel, and trans. So I snagged a 2010 4.0L 5 speed trans as my truck was a 3.0L. I pulled both transmissions down to install my shorter 3.0L 1st-3rd gear in the 4.0L trans with all new syncros, bearings, and swapped over my tailhousing with t case linkage mounts. I use this as a work truck out in the woods, so I wanted the lower first gear (3.7 vs 3.4). The only difference I found between the two transmission is the spacer that goes between 5th and reverse. Otherwise, everything was identical.
Adapter kit mounted up perfectly!
Had a slight interference issue between the front diff and the passat oil pan, so off to the parts stash for a jetta oil pickup and pan!
Quick baffle
Much more betterer!
Looks so little in there!
Since you have to drop the front diff to get to the driver side motor mount bolt anyway, figured it was a good time to clean up the 4.10 junkyard front end and put it in.
The adapter kit is set up to use a 4.0L clutch, flywheel, and trans. So I snagged a 2010 4.0L 5 speed trans as my truck was a 3.0L. I pulled both transmissions down to install my shorter 3.0L 1st-3rd gear in the 4.0L trans with all new syncros, bearings, and swapped over my tailhousing with t case linkage mounts. I use this as a work truck out in the woods, so I wanted the lower first gear (3.7 vs 3.4). The only difference I found between the two transmission is the spacer that goes between 5th and reverse. Otherwise, everything was identical.
Adapter kit mounted up perfectly!
Had a slight interference issue between the front diff and the passat oil pan, so off to the parts stash for a jetta oil pickup and pan!
Quick baffle
Much more betterer!
Looks so little in there!
9
Figured out a 2004 jetta accessory bracket works just fine! Oem oil filter/cooler housing just barely fit also. Got the modded oem jetta coolant bypass line wrapped around the backside of the motor too. The passat line didn't want to play happy.
A 2004 passat tdi fuel pump fits the ranger sending unit perfectly! Deleted the fuel pressure regulator and using evap line as fuel return. Took the evap line off the back end of the fuel tank and tee'd into the vent line for the gas tank so that section of the fuel tank will now fill with fuel.
Got the intercooler all done too. Made the end tanks out of 1/4" plate to handle the intended 60psi of boost.
Welded decent for a $112 chinese core
A 2004 passat tdi fuel pump fits the ranger sending unit perfectly! Deleted the fuel pressure regulator and using evap line as fuel return. Took the evap line off the back end of the fuel tank and tee'd into the vent line for the gas tank so that section of the fuel tank will now fill with fuel.
Got the intercooler all done too. Made the end tanks out of 1/4" plate to handle the intended 60psi of boost.
Welded decent for a $112 chinese core
I remember a thread on the sloppy mechanics Facebook page where someone had blown out one of those cheap intercoolers
I don't know if it would help, but you could probably weld some strips of aluminum from the top to the bottom of the intercooler on the finned section to try and prevent that. 60psi is quite a lot of boost lol
Example pic of what I'm talking about
I don't know if it would help, but you could probably weld some strips of aluminum from the top to the bottom of the intercooler on the finned section to try and prevent that. 60psi is quite a lot of boost lol
Example pic of what I'm talking about
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