TDI Ranger Build




Rock Auto 5% Discount Code: 173A8B749AB83C Expires: January 1, 2020

ldriver

New member
Joined
Aug 3, 2018
Messages
5
Reaction score
0
Points
0
Location
Glendive, Montana
Vehicle Year
1985
Make / Model
Bronco2
Engine Size
2.8
Transmission
Manual
I have a wiring diagram for a 1985 Bronco, both gas and diesel.
 

ldriver

New member
Joined
Aug 3, 2018
Messages
5
Reaction score
0
Points
0
Location
Glendive, Montana
Vehicle Year
1985
Make / Model
Bronco2
Engine Size
2.8
Transmission
Manual
Looks like the 308th gave you longer range.
 

Bret2094

New member
Joined
Jan 2, 2019
Messages
2
Reaction score
0
Points
1
Location
Bryan, TX
Vehicle Year
1997
Make / Model
Ranger
Transmission
Manual
I'm also disgusted that none of the big three feel it is important to offer these trucks to the public.

I'm looking to offer a kit.
Sorry for bringing up such and old post, but did you ever decide to offer an adapter kit/ find a vendor to sell them? I've got the 2.3L in my ranger, and I've got a donor Jetta sitting in my back yard ready to go. I've not found anywhere that offers the 2.3 pattern adapters

Bret
 

bobbywalter

TRS Technical Staff
TRS Technical Advisor
TRS Banner 2012-2015
TRS 20th Anniversary
Joined
Aug 9, 2007
Messages
18,893
Reaction score
381
Points
83
Location
woodhaven mi
Vehicle Year
1988
Make / Model
FORD mostly
Engine Size
BIGGER
Transmission
Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
theres 3.0 and cologne v6 2.8/2.9/4.0 adapters around.

real easy to sell your 2.3 trans and get one of the other units. minor cost difference...may even be cheaper if you trade right.


i am sure you have come across this sight.

http://gastodiesel.tdconversions.com/adapter/


pretty reasonable setups. swapping a v6 unit in place of your current unit changes nothing save for allowing you to easily adapt the tdi.
 

Bret2094

New member
Joined
Jan 2, 2019
Messages
2
Reaction score
0
Points
1
Location
Bryan, TX
Vehicle Year
1997
Make / Model
Ranger
Transmission
Manual
theres 3.0 and cologne v6 2.8/2.9/4.0 adapters around.

real easy to sell your 2.3 trans and get one of the other units. minor cost difference...may even be cheaper if you trade right.


i am sure you have come across this sight.

http://gastodiesel.tdconversions.com/adapter/


pretty reasonable setups. swapping a v6 unit in place of your current unit changes nothing save for allowing you to easily adapt the tdi.
I've seen these, just mainly thought I'd try to support the guy that put the info out there to swap. Started looking about a month ago for a decent 5 speed that was either behind a 3l or 4l. So far I mainly see the 2.3 5 speeds, and the ones I do find for the bigger engines are at a 400+ dollar price point. Didn't figure it hurt to ask


Bret
 

RangerSVT

Oct 09 OTOTM
Article Contributor
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
RBV's on Boost
ASE Certified Tech
TRS Banner 2010-2011
TRS Banner 2012-2015
Joined
Mar 15, 2009
Messages
7,886
Reaction score
51
Points
48
Location
TRS since 2002 - NW KY
Vehicle Year
19962002
Make / Model
Ford
Engine Size
GT-40 5.0L EFI W/AC
Transmission
Automatic
GG, time for a bump, and my latest ideas. Got an 03\2000 auto beetle. Broke timing belt and bent a valve or 6. Head was pulled, repaired, and 6 new valves. So ive been looking at doing twin turbos with this one, going auto into a 90 bronco 2 with full width 44\8.8 axles, 4.56 gears and 37s.
On the fuel side, since i have the auto and 11mm IP, what injectors\nozzles would you recommend?
On the twins, ive been reading a 45mm is a good popular choice. I have a baby H1C from a 4bt, which happens to be a 45mm. I was initially going to use a stock turbo from a 91 DT466 as i have one thats a new zero mile unit.
My power level goals would be just shy of upgrading internals. Im already planning ARP studs, i need to do more reasearch as to what head gasket i need (1, 2, 3 hole) as i dont know the differences. I'm still learning about it, and what ill actually need from the donor for the swap. Thanks for any info you can pass my way.

SVT
 

Exenos

Member
Joined
Nov 4, 2012
Messages
98
Reaction score
0
Points
6
Location
Ontario
Transmission
Manual
GG, time for a bump, and my latest ideas. Got an 03\2000 auto beetle. Broke timing belt and bent a valve or 6. Head was pulled, repaired, and 6 new valves. So ive been looking at doing twin turbos with this one, going auto into a 90 bronco 2 with full width 44\8.8 axles, 4.56 gears and 37s.
On the fuel side, since i have the auto and 11mm IP, what injectors\nozzles would you recommend?
On the twins, ive been reading a 45mm is a good popular choice. I have a baby H1C from a 4bt, which happens to be a 45mm. I was initially going to use a stock turbo from a 91 DT466 as i have one thats a new zero mile unit.
My power level goals would be just shy of upgrading internals. Im already planning ARP studs, i need to do more reasearch as to what head gasket i need (1, 2, 3 hole) as i dont know the differences. I'm still learning about it, and what ill actually need from the donor for the swap. Thanks for any info you can pass my way.

SVT
Might as well go all the way to .320/.360 nozzles with the 11mm and compounds. You'll have to go to European vendors for those sizes. One of the big power guys over on tdiclub worked out a few suggestions for compounds on a 1.9 and a gt2052 (37mm) and a 10 or 12?cm hx35 (56mm?) were one of the combinations. The small housing on the hx was key. I'd bet a hy35 or maybe even a he351 would be even better with the smaller housing. Not sure what housing cummins put on a baby h1c, hopefully its not massive like the 18 or 21cm on the 1stgens. The head gasket depends on the piston protrusion. You can find a chart for finding which you need.
 
Last edited:

RangerSVT

Oct 09 OTOTM
Article Contributor
V8 Engine Swap
OTOTM Winner
Solid Axle Swap
RBV's on Boost
ASE Certified Tech
TRS Banner 2010-2011
TRS Banner 2012-2015
Joined
Mar 15, 2009
Messages
7,886
Reaction score
51
Points
48
Location
TRS since 2002 - NW KY
Vehicle Year
19962002
Make / Model
Ford
Engine Size
GT-40 5.0L EFI W/AC
Transmission
Automatic
So I found the Baby H1C (4bt) came with 8cm and 12cm turbine housings, and H1s came with 44mm, 46mm, 50mm, and 56mm compressor side. I never measured which one I have. I'm guessing the baby H1C got the 44mm and 46mm housings. I'll try to measure mine this weekend. It's nice to know I can step up compressor sizes if I run out of air..
I'm planning a 4R70W trans, and my power goals are 200-250hp, about 400 tq. I can tune for the trans shifting, which is why I'm leaning to go with that trans...

SVT
 

RamblerRyGuy

New member
Joined
Sep 9, 2019
Messages
6
Reaction score
0
Points
1
Location
Ohio
Vehicle Year
1995
Make / Model
Ford Ranger
Transmission
Manual
Adapter Development

It's been a long time coming but I finally have something to show for the last year of research, design, prototyping, etc.

The basic process started with several gutted and cleaned transmissions which were brought in and measured with a CMM. Repeat the process with VW flywheels, Ford flywheels, starters...you name it and get to modeling:







At this point I had a prototype or two lasered out of 14gauge sheetmetal to see how things were shaping up. I'm glad I took this intermediate step as I would have wasted two plates with simple but important revisions.

I decided I was far enough along that I wanted to cut up a plate on my third rev. I held my breath when I slipped it on the first time and she fit like a glove.



Slip on the transmission for good measure:



And away we go. The hard part is done. :icon_bounceblue:
I know I'm a bit late to the party on this one, but how did you make the new starter position fit with the Ranger transmission, since it's not located where the stock Ranger starter pocket is anymore?
I'm working to make my own adapter for my 4.0 Ranger and everything is working out fine except I'm running into starter location issues. Knowing what you did to solve the starter location issue would help me immensely.
Thanks!
 

RamblerRyGuy

New member
Joined
Sep 9, 2019
Messages
6
Reaction score
0
Points
1
Location
Ohio
Vehicle Year
1995
Make / Model
Ford Ranger
Transmission
Manual
Fuel System, Part 1

The Ranger of course was fuel injected which meant it's in-tank fuel pump was putting out around ~60psi of fuel pressure which is way more than the 4-7 psi I need for the tdi. So I need to drop the tank to get at the fuel pressure regulator which is also mounted to the sending unit which is convenient since I also need to drain 1/2 of tank of 6 yo gasoline.

Out comes the tank, my fuel pump used to de-fuel mis-fueled tdi's and my spare battery:



Out comes the sending unit so I can get every last bit of gas out:



And here's the sending unit:





In the above pictures you can see the fuel pump, fuel pressure regulator and some sort of EVAP check valve. I'm going to remove the last two and reuse the connectors on the sending unit for return lines (more on that in Part 2).



Here are the connectors as they are installed on the Ford lines. I simply cut a slit to remove them from the lines.



And here they are on the sending unit:



I wasn't too crazy about the return lines the way they were on the top of the sending unit - I figured they would aerate the fuel when the fuel level was below 3/4 tank. To remedy this I went to the bone yard and picked up a sending unit from a diesel superduty for the stainless lines. Don't laugh, this was my first attempt at TIG welding stainless.



It appears there is the normal stock pickup tube with the sock, but then there are two other lines in addition to it. What are they both for? One has to be a return line. But what is the other one's purpose? I'm trying to figure out for my own TDi ranger build.
Thanks
 

Obiwanprof

New member
Joined
Aug 20, 2019
Messages
4
Reaction score
2
Points
3
Location
Sarnia, ON, Canada
Vehicle Year
2002
Make / Model
Ford, Ranger
Engine Size
3 litre
Transmission
Automatic
2WD / 4WD
2WD
On my 2002 The big line (roughly 1/2" OD) is the EVAP suction line.
 


Top