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B3000 TDI swap


Whitbread

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Interesting swap, I like my ALH but it'll stay in the wagon. I skimmed the posts but didn't see, is there a reason you went mk5? I'd love to see some VAGCOM data on this build if you want to share.
Cost. I actually wanted go run a jeep liberty 2.8L as it's a much heavier duty engine. But I found a cheap BHW passat motor first. So I went that route.

What data do you want to see?

I’m assuming you have to cut some of the transmission was to clear the new starter location? I’m custom making my own adapter plate and the starter location is my biggest problem currently. I don’t want to weaken the transmission overly, but that starter location is the only option.
Yes, if you look closely, the bellhousing is notched for the starter pinion. No problems since.
 


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Whitbread

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Scored a jk Rubicon transfer case to go with my nsg370 for $600! Also got a pair of 1310 yokes and a front driveshaft in a box kit from JE Reel Driveline when I was in LA last week. Getting closer!

 

Whitbread

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All the parts are ready to swap the nsg370/241OR in the ranger! I sold the ranger transmission/tcase and ford 4L adapter kit off with all the spare parts so it's time to get busy.

The last part I had to make was the shift rail support for the jeep trans. The factory setup has molded plastic on a thin piece of stamped steel that guides the 4 shift rails. When the plastic breaks, the rails fall out of alignment and cause all partial engagement/popping out of gear issues that nsg370's have a reputation for. This is cnc'ed out of 954 bronze and double the thickness of the oem plastic part.

Broken oem shift rail support


New shiny parts


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A few weeks back I finished development of my tdi to 4L jeep adapter kit, will hopefully bolt it on on sunday!


 

PetroleumJunkie412

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ericbphoto

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:iamwithstupid:

Very nice work.
 

Whitbread

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Thanks for the kind words guys! I didn't quite get the trans in today, but I did get the leaking vacuum/fuel pump resealed, leaking water neck o ring changed, and adapter kit/starter all installed and torqued up. Trans is going in first thing in the morning!

The black hole


Resealed vac/fuel pump




It all fits!
 

Whitbread

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The truck is up and running! It was 110% worth it. It is soooooooo much better to drive now. This is proper work/play gearing for a truck and how it should've been from day 1. First gear dropped from 3.7 to 4.45, reverse from 3.4 to 4.0, and low range from 2.48 to 4:1.

I had to modify the cross member slightly and used a jeep transmission mount instead of the ranger mount. The rear driveshaft was lengthened by 5" and used a neapco 1310 driveshaft kit to build the front shaft. For the hydraulic clutch connections, I used an advanced adapters TJ jeep -3an fitting in the master cylinder and I tig welded a -3an male onto a VW clutch line quick connect end that just happened to match the JK slave perfectly. An all star performance 24" -3an line with a 45 on one end was the perfect length and on the shelf at the local auto value.

As it turned out, the factory ranger master didn't have enough fluid displacement to fully disengage the jeep slave/clutch. Browsing rock auto, the ranger master is a 16mm bore and the jeep slave was paired with a 19mm bore master. Poking deeper on rock auto, all 2000 era f150-f550 used the same appearing master cylinder as a ranger but with an 18mm bore. It installs in the same way as the ranger master, but I found out the hard way that the square shape on the F150 master that twists into the bracket is .100" larger than the ranger master was. I used a flex shaft dremel with an aluminum burr bit to open up the square in the bracket and it twisted right in. Once bled, the clutch now fully disengages!

For the transfer case shifter, I whipped up a linkage using some 1/4" rod ends and other bits laying around the shop. Rummaging in the scrap bin, I found a nice 1.25" chunk of round that made a perfect shift knob. The pivot has a teflon bushing pressed in riding on a stainless shoulder bolt and it works very smoothly without being floppy. Last things to do are connect the reverse lights, cut holes in the 2wd auto floor plate, install junkyard sourced 2wd auto rubber floor mat in place of nasty carpet, and install the chevy squarebody shiftboots. Just happy to have my truck back!





2 Hi shifter position

4 low shifter position


Here's a video running up through the gears and showing just how low the crawl ratio is now.


 
Last edited:

PetroleumJunkie412

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4WD
My credo
Give 'yer balls a tug. Fight me.
diesel doesn't interest me.

But this does.

Hm.
 


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