B3000 TDI swap


Whitbread

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Whipped up a pulley hub to remove the clutch fan




Got some awesome news today! After calling more wrecking yards than I can count, I finally scored a complete 03 fx4 manual t case shifter linkage, both shifter arms, boot/bezel, and floor plate with intact boots for $145 shipped :yahoo: :yahoo:. Getting under the truck to shift in/out of 4wd has been getting very annoying lately.
 
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Whitbread

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Clutch showed up today!


Adapter in progress to bolt hp turbo to exhaust manifold.
 

Die.Fledermaus

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Why delete a manual fan, you know what all OEMs prefer to use in normally clocked front engine vehicles? Increasing cost and lower durability seems counter productive.
I'm new to water cooled stuffed (very), my B2 is the very first for me.
 

Whitbread

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Why delete a manual fan, you know what all OEMs prefer to use in normally clocked front engine vehicles? Increasing cost and lower durability seems counter productive.
I'm new to water cooled stuffed (very), my B2 is the very first for me.
Because the vw clutch fan is small, low mounted, off center, and going to be ~10" away from the ranger radiator.


Finished up the turbo adapter plate.


 
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Whitbread

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Wohoo! Goodie box from a junkyard in Oregon showed up today! I'll finally be able to shift into 4wd without crawling under the truck!

 

Whitbread

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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. For anyone else doing something similar, the threads in the extension housing are english, not metric! Threw me for a hell of a loop. I'd love to find the engineer responsible for keeping SAE threads on a metric truck.




Finally! Don't know if I want to fix the trim rings for the fx4 boots and make a plate to cover the carpet mismatch or find some 91-97 shift boots.
 
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Whitbread

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Decided to try gluing the fx4 bezel back together and whipped up a quick piece of aluminum to cover the carpet mismatch. I think it turned out well enough for a work truck!

 

Whitbread

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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 :D.

I'm not bothering to hook it up yet, just doing this 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.



 
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bobbywalter

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Why delete a manual fan, you know what all OEMs prefer to use in normally clocked front engine vehicles? Increasing cost and lower durability seems counter productive.
I'm new to water cooled stuffed (very), my B2 is the very first for me.
your serious?


have you looked under the hood of anything 400 hp and rwd lately?

increase cost...potentially. lower durability. no.

violate kiss principle-yes but benefit can outweigh the penalty.

for what this thing is....electric fan wins every time.




that snorkel....i would shred off of my truck, i have to go out of the top of the cowl....and still fawk em up sometimes. bt if your going near bumper deep water...its worth doing ime.
 

Die.Fledermaus

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So funny story, I needed to cross Syskiyou summit (twice, think 4,000 elevation) to retrieve a mark 5 with a bricked DSG and I borrow my neighbors 2500HD. This thing is pretty modern, more cup holders in reach of the driver than I have in my entire fleet, common rail, factory tow package, some sort of self shifting transmission called Allison, air conditioned glove box. But it is 400hp and rear wheel drive.

Wait for it.

Wait for it.

Wait for it.

Wait for it.

Gasp, it has a mechanically driven cooling fan clutch!

Holly crap, I still see this as somewhat normal. Shrug. But I get the length/offset to radiator as a good reason to go electric.

I really don't care. All I was after was what I think is a 160,000 mile BRM (pumpe duse) donor, far from perfect (yet far better than I expected), that I got cheap.
 

Motohead1

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Photobucket fix works great. Thanks!

Any updates?

I see you have done a few of these swaps. How much intercooler do you usually need? Or to be more specific at what intake temp does timing or fuel get pulled? My ALH swap runs about 30 above ambient when warmed up but I also put the MAP in the intake and I am wondering if that was a mistake and if I should put it immediately post intercooler like stock.
 

Whitbread

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Photobucket fix works great. Thanks!

Any updates?

I see you have done a few of these swaps. How much intercooler do you usually need? Or to be more specific at what intake temp does timing or fuel get pulled? My ALH swap runs about 30 above ambient when warmed up but I also put the MAP in the intake and I am wondering if that was a mistake and if I should put it immediately post intercooler like stock.
Yes! A huge update actually, my adapter kit FINALLY came in last week so the 3.slow is coming out at 7am tomorrow morning :yahoo:


Since these last pics I also 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.
 
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planeflyer21

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Nice Whitbread!

I'm really looking forward to your progress. Hoping that mine comes together in January or Fedbruary.
 

Motohead1

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Caint beat Randys adapters. His work is top notch.
 


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