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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 March 31st, 2017, 07:08   #46
jimbote
 
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Location: spiral arm, milky way (aka central NC)
Fuel Economy: golf=38-43mpg...tacoma tdi=29-33mpg
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Originally Posted by CF-FZD View Post
You like it..?
Please tell me you know of a super strong clutch that will help put the power to the ground. Toyota r150 trans.

love it ! .... as far as clutches go my current setup with a 10" ctx-107 pressure plate and dtx-136 disc has held up the best but it's started to slip under heavy load ... i'm now looking at the competition brand dual friction clutch as a replacement
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Old March 31st, 2017, 07:11   #47
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wow, looks like a ripper. Can't tell if your clutch is slipping or if that is wheelspin. Awesome work.
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Old April 2nd, 2017, 08:56   #48
CF-FZD
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Quote:
Originally Posted by jimbote View Post
love it ! .... as far as clutches go my current setup with a 10" ctx-107 pressure plate and dtx-136 disc has held up the best but it's started to slip under heavy load ... i'm now looking at the competition brand dual friction clutch as a replacement
Please post an update when you change the clutch out. I'm running a flywheel from a 22re that's been drilled to fit the VW crank. I haven't completed the brake in period (only 10-15km so far) so I really shouldn't be driving it hard.

What flywheel are you using and have you tried the Marlin crawler setup, the rock crawling guys say they are great but they don't have 300lb/ft of torque at 2400rpm like a big turbo TDI.

-------

In my video I think it was part wheel spin on the dusty road and part clutch slip as it was in the first 5 min of driving on the clutch😳. I'll be good to it from now on.
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02' Jetta TDI is the DD.
1966 Ford F100, crown vic suspension swap, ALH TDI. 11mm, GTB1756vk, .216, 3" exhaust, FMIC, Malone stage 5, Toyota 5 speed.
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Old April 12th, 2017, 18:41   #49
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Truck is on the road now, I've put a few hundred trouble free kilometres on it and everything is working a expected. Fuel mileage was 9L/100 on the (166km) trip I checked while doing 110-115km/h with some stop and go traffic. It has more then enough power to move the truck down the road, it's much faster then my 02' Jetta with a 1.5 tune. So far I've had it doing 150km/h. The GTB1756 starts to spool at about 19-2000 and hits 27psi by 2400rpm it keeps pulling right past 4000. I wouldn't change a thing with the performance. To my surprise the clutch I have is holding just fine, it's just a bit grabby when taking off with low rpm. It holds well enough to spin the tires in first and second on dry pavement or a full boost pull up a hill in 5th.
The biggest downfall so far is the exhaust and engine noise. It currently has 3" strait off the turbo, a 4" long 3" fleet pipe then a 2 bolt flange just aft of the firewall. Then about 4' of 3" pipe and a bend then exits just ahead of the back right tire. I have enough pipe and a bend to make another back half. I'm on the hunt for a 3" free flowing muffler that will quiet down the drown. The floor of the truck already has some insulation and full carpet.
The truck had a sturdy rear bumper so I decided to make it into a trailer hitch. I bought a receiver and a 2" ID hitch tube. Cut the hole and welded it in. When the hitch isn't in use I can leave it in but facing the opposite way out of site under the truck. I'll limit towing to 3500lbs or so.
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02' Jetta TDI is the DD.
1966 Ford F100, crown vic suspension swap, ALH TDI. 11mm, GTB1756vk, .216, 3" exhaust, FMIC, Malone stage 5, Toyota 5 speed.
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Old April 12th, 2017, 19:08   #50
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very cool .... thanks for the update... does the turbo feel laggy at all ?
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Old April 12th, 2017, 19:53   #51
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Nice. What rear gear are you running?
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Old April 15th, 2017, 04:53   #52
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Quote:
Originally Posted by jimbote View Post
very cool .... thanks for the update... does the turbo feel laggy at all ?
Not at all it spools as fast as my stock turbo ALH Jetta (Malone 1.5). The difference between the two is I may have to drop a gear in the truck where I may have stayed in 3rd in the car. It may all be in my head but in the car I'll turn onto my street and climb a hill, in the car I'll start the pull in 3rd at 17-1800 but the truck needs the drop to second. It will accelerate in 3rd but takes a few seconds to spool and puts out a lot of smoke before the boost hits. I tend to just drop to 2nd and it pulls away smoke free. Other factors may be the truck is 3-400lbs heavier then the Jetta, the gear ratio in the trans and diff are different and I probably take the corner slightly faster in the car. If I give the truck full throttle in 2nd on a corner it will go sideways and that's not a good idea when I'm on my own street. In a strait line it will spin the Goodyear Eagle GT tires in first and second without using the clutch. I have absolutely no complaints about the power and have no desire to squeeze more out of the engine. That said I may have found a Ford Coyote 5.0 and a 6 speed manual from a 14' mustang for a good price. If I buy it I'll be doing another engine swap next winter.

-----
The gearing in the truck 9" rear is 3.31/1 I think. It has 235/55/17 tires and revs about 2400 at 100km/h (62mph). 3800 @ 147km/h (90mph). I may try to find a set or 235/60 or 253/65 tires for the rear and see how it does. The speeds were done with the iphone gps.
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02' Jetta TDI is the DD.
1966 Ford F100, crown vic suspension swap, ALH TDI. 11mm, GTB1756vk, .216, 3" exhaust, FMIC, Malone stage 5, Toyota 5 speed.

Last edited by CF-FZD; April 15th, 2017 at 04:56.
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Old April 22nd, 2017, 06:39   #53
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A little towing action with the TDI Ford. I plucked my boat (bayliner 2651) from the farm where I store it to my house to get it ready for water. I think it weighs about 5500 plus the 1500 trailer about 7000 pounds. The truck is #3400 on its own 10k in all. 2400rpm in 4th gear, 80km/h, 10psi boost it would sit at 400*C EGT and 500-600 degrees C if I held 80 up any hills. Climbing away from a stop sign up a hill was interesting, trying not to spin the tires at first then a steady 600 on the EGT in first gear at 3000rpm. Plenty of power to go faster on level ground but it was a big load for the truck.

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02' Jetta TDI is the DD.
1966 Ford F100, crown vic suspension swap, ALH TDI. 11mm, GTB1756vk, .216, 3" exhaust, FMIC, Malone stage 5, Toyota 5 speed.
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Old April 22nd, 2017, 07:46   #54
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...Wow!
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Old April 22nd, 2017, 19:20   #55
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Thats great. Love to have seen the faces of people as you passed by.
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Old May 6th, 2017, 21:23   #56
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Wow! Better than I would have expected for mileage! Looks great and sounds great! Trying to do the same thing in a 83 f150. Gives me some push! Good job!
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Old May 22nd, 2017, 17:06   #57
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The old truck goes down the road rather well

https://youtu.be/nI-nUh8XJzw
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02' Jetta TDI is the DD.
1966 Ford F100, crown vic suspension swap, ALH TDI. 11mm, GTB1756vk, .216, 3" exhaust, FMIC, Malone stage 5, Toyota 5 speed.
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Old May 22nd, 2017, 17:19   #58
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Very Nice!
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Old May 22nd, 2017, 19:44   #59
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well done vid .... a few years ago folks didn't think a lil' 1.9 would even tote a 4x4 yota with ease, now seeing them in full size trucks and mid size pigs like durangos and dakotas ... lot to be said for power density
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Old May 22nd, 2017, 20:27   #60
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Man thats a clean truck. Its hard for dust to settle on things at 100MPH.
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