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TDI Conversions Discussions on converting non TDIs into TDIS. More general items can be answered better in other sections. This is ideal for issues that don't have an overlap and are very special to swaping engines.

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Old February 8th, 2017, 18:35   #1
Join Date: Jul 2016
Location: Barrie, ON
TDI(s): 03 Jetta
Default 1966 Ford F100 ALH build

The Ford truck forum guys would think I'm crazy, hotrod people just don't understand. So I'm here with my F100 build. I drive a 01' ALH Jetta as my DD 330k on the clock and it works just fine. I bought the F100 in September 2016 with plans to put a TDI in it right from the start. The truck was as close as I could afford to perfect, it has no rust, nice interior, and it passed the safety check no problem. On the bad side it drove like crap, manual steering and 4 wheel manual drum brakes. Fords first version of independent front suspension the "Twin I Beam". The engine was the original 352FE big block (172hp net) and a 3 speed auto. The truck weights 3800 lbs as it was from Ford.

My plan was to pull the engine and sell it, then change out the complete front suspension and replace it with one from a Crown Vic. Then instal a VW ALH & Toyota 5 speed I picked up from a friend.

The suspension is in, sway bar, brakes, engine mounts, clutch pedal, power steering lines. Are all done. The front clip is back on and I'm about ready to start into the wiring and cooling system.

The engine is out of a 2003 Jetta auto that was well maintained and had 430k. Here is a list of the modifications & performance parts: 11mm pump, .216, GTB1756vk (vacuum converted), AFN manifold, darkside adapter, 3" mandrel bent exhaust, front mount intercooler, 2.25" plumbing, 3 bar map, Malone custom stage 5 tune. I'd like to see close to 200hp and 300 lbft.
My goal for the truck is a seasonal daily driver that I can drive to work 180km round trip 7-8L/100km. I want modern handling, efficient and reasonably powered truck that looks cool. It should handle and stop well with the 11.5" rotors twin piston calipers and suspension from the 2010 police car. I'm guessing it should drive out of my car garage at about 3500lbs and its now 5" lower then stock.

I know the questions are going to come up so I'll answer them now.
Why not keep the V8? Answer 25L/100km
Why not a 4bt? Answer 900lbs and 110hp not efficient.
Coyote/LS? That may be in the future if I'm not happy with the TDI.
It's too heavy for a TDI. Answer maybe so, but my Jetta TDI (stage 1.5) does fine with 4 guys in it and I'll have 50% more power for the same weight.

Last edited by CF-FZD; February 8th, 2017 at 19:03.
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Old February 8th, 2017, 18:52   #2
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Join Date: Dec 2015
Location: Dunsmuir,Ca.
TDI(s): ALH Samurai
Fuel Economy: pending

You'll have a shipton of room in the engine bay to put it wherever fits best.
Did you rebuild the engine,a stage 5 tune on an engine with 430K seems
like asking for trouble.
Edit: Aha,there's the photos,looks good.

Last edited by 1.9ZOOK; February 8th, 2017 at 19:27.
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Old February 8th, 2017, 19:21   #3
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Join Date: Jul 2016
Location: charlotte

I like this alot!
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Old February 8th, 2017, 19:25   #4
Join Date: Sep 2014
Location: oHIo
Fuel Economy: 50

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Old February 8th, 2017, 20:11   #5
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You could learn ballet and dance in the bay as you work on that thing. Kudos! Welcome! I might suggest a compound setup in your future for low end torque.
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Old February 8th, 2017, 23:22   #6
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Join Date: Jul 2006
Location: spiral arm, milky way (aka central NC)
Fuel Economy: golf=38-43mpg...tacoma tdi=29-33mpg

it'll do fine, my toyota is around the same weight and it's pretty quick ... nice swap
'You know what? This is a business.' So, now, I just keep my mouth shut and pet my chihuahuas." Mickey Rourke
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Old February 9th, 2017, 00:32   #7
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Join Date: Dec 1999
Location: Leamington, UT

Impressive. Very classy old Ford. Love it!
2003 Jetta Wagon TDI 6M(DRW/Peloquin). 11mm IP, VNT 17/22, Franko6 Stage II Cam and injectors, Rostens, BHW 81.5mm pistons, TDTuning Race Tune.
2015 Passat TDI SE 6M. 2 stage fuel filtration with Nicktane filter head, Sigma 6 Short Shifter, Panzer Plate.
2005 Passat TDI GLS 5A. Franko6 Chrome Cam, BSM deleted with BRM pump.
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Old February 9th, 2017, 05:56   #8
Veteran Member
Join Date: Aug 2013
Location: Vermont
Fuel Economy: 45mpg avg

awesome swap!!
current: 03 jetta wagon (pp520, malone stg3, straight pipe), ford tractor with saab turbo, Snarling Audi 90q AHU swap (holset he211w, 32psi, race 520's)
past:11 second audi 90 20vt monster, 20vt swapped audi 90 winter beater, 10vt swapped 4kq with efi and many many other 5 cylinder audis, and a few 1.8tq's
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Old February 9th, 2017, 06:17   #9
Veteran Member
Join Date: Nov 2002
Location: Kingdom City, Missouri
TDI(s): 2014 Touareg

Wow, that brings back memories. I learned to drive in Dad's '65 F100 with the TWIN I Beam fender plaque. Straight 6, three-on-the-tree. It was my "dragster" when he and Mom weren't home.
The ALH should handle it fine with your mods.
2014 Touareg Sport (Hers)
2000 Jetta 5spd Smyth Ute conversion
2003 CTD 6spd Q/C
Proud to be called Grandpa x 7
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Old February 9th, 2017, 12:28   #10
memphis tdi
Veteran Member
Join Date: Dec 2005
Location: Memphis

I bet a warmed up tdi would be fun in my 2400lb 62 falcon.....
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Old February 9th, 2017, 12:40   #11
BleachedBora's Avatar
Join Date: Oct 2003
Location: Gresham, Oregon

Excellent swap, looks great! I love the plane even more

When I had some 1.4 PD and 1.6 CR complete TDI's kicking around I was in very very early talks with Ariel on throwing them in some Atoms for a limited diesel production run. Never materialized but I thought it would be super cool nonetheless!

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Old February 9th, 2017, 18:45   #12
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Join Date: Nov 2014
Location: maine

Very cool!! Hard not to get nostalgic over the classic pickups.
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Old February 12th, 2017, 18:56   #13
Gordon Peterson
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Join Date: May 2006
Location: Rockford MI
Fuel Economy: 40mpg

Love your build. Guess I better start my thread on my 59 f100.
Good luck with your build. I love these old F100's and think your alh is a great engine choice.. more torque than original engine in the truck.
03 Jetta TDI wagon "SMOKE" (mine)
trusted guru's: r90sKirk, JETaah, Franko6
Heads nozzles,TB kits, etc.: Franko6

Last edited by Gordon Peterson; February 13th, 2017 at 13:06.
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Old February 13th, 2017, 11:18   #14
Join Date: Apr 2016
Location: Thousand Oaks
TDI(s): None yet

Looking forward to this build!

Did you decide to stick with the 5 speed or go with an AW4?
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Old February 13th, 2017, 14:18   #15
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Join Date: Sep 2006
Location: Ontario, Canada
TDI(s): Too many.
Fuel Economy: Depends on what I'm towing!

Nice plane Send me the coordinates of your strip and I'll "drop" in to check out your truck in the spring!
2004 Passat W8 Variant, awaiting BHW swap
Retired: 2005 Passat BHW Variant w/01E 6 gang
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