Tdi Ranger

jimbote · Jul 23, 2011

83stang said:
images didn't appear...got them here

four cylinder or V6? ....something doesn't look right....the VW pattern is small like the ford....where did you get the measurements for the TDI flywheel bolt circle?

jimbote · Jul 23, 2011

greengeeker said:
So did you redrill the vw pattern between the ford pattern or did you reuse some of the holes? I don't know how you would do the latter as the ford bolt holes are probably 2mm bigger. tia

I know the V6 ranger flywheel bolts are 10x1 just like the VW ...not sure about the 4 cylinder...they may be 7/16?

greengeeker · Jul 23, 2011

jimbote said:
four cylinder or V6? ....something doesn't look right....the VW pattern is small like the ford....where did you get the measurements for the TDI flywheel bolt circle?

Looks like the v6.

greengeeker · Jul 23, 2011

jimbote said:
I know the V6 ranger flywheel bolts are 10x1 just like the VW ...not sure about the 4 cylinder...they may be 7/16?

Not sure. Have both a vw flex plate and a 2.3L flywheel at work and will be measuring bolt patterns, etc.

83stang · Jul 24, 2011

Was away for the weekend so i'm getting back to you guys now.
It's from a 99 4.0L V6. I wanted the 4.0 flywheel because of the bigger clutch.
Ya it defiantly has 10mm bolts I measured with my vernier.

I got the VW flywheel drawing from this thread:
http://www.yotatech.com/f162/vw-diesel-build-up-135203/

Ya this bolt pattern is tiny and if i was going to redrill it i would have to do more modification then i would like to, too the flywheel, maybe compromising it's strength.
If someone has a corrected VW flywheel bolt pattern or if someone can tell me the 4 cylinder has a bigger bolt pattern making it easier to modify that would be awesome.

greengeeker · Jul 24, 2011

The 4cyl bolt pattern is very close- the pattern diameter might be identical. Looks like you can simply redrill without any other modification.

83stang · Jul 24, 2011

Ok so then tomorrow i'll call the wrecker and exchange the flywheels. They show on their site they have a 1998 4cyl flywheel in stock. Thanks a lot guys.

I would just not feel comfortable modifying the 4.0 v6 because of how small and different it is.

greengeeker · Jul 25, 2011

Do the 2.3L turbo Mustangs utilize the same flywheel/clutch? If so, then one shouldn't have trouble finding a clutch to hold TDI torque.

83stang · Jul 25, 2011

I'm pretty sure the turbo flywheel is the same pattern. Because people swap the turbo flywheel onto the regular 2.3 and vice versa. Plus that motor remained virtually unchanged from 1979 until 2003 when they switched to the duratec engine. The M5OD trannys been used from 93 till now according to the ranger station tech section. So lots of ranger stuff is interchangeable which is awesome. I was looking up clutches and you can buy a pretty reasonably priced heavy duty clutch for the 2.3's so i don't think power is a huge issue. If the stock clutch slips I'll just buy a performance one.

I went to exchange the flywheel today and I guess the one they pulled out of the truck was heavily damaged so off to look for another one.

Lone Ranger · Jul 29, 2011

If I can remeber 4 years ago, I'm remembering just elongating a couple of holes. I can pull it out and snap a few pics if you want. I don't think i had to enlarge the other holes. The pain is the pilot bearing. For the life of me I can`t remember where that came from. But i assure you there is a bearing the fits the back of the TDI crank and accepts a M5OD-R1 input shaft.

As for the clutch, it holds no problem, don`t worry about a performance pressure plate or anything.

Lone Ranger · Jul 29, 2011

Well out of curiosity I went and did it. It does appear that i had to tweak all the holes, some barely noticably if any. But as you can see only one a fair bit

Also I'll include a pic of the adapter plate for ****s and giggles

Lone Ranger · Jan 31, 2015

Extensive Fuel Log

Here is my log of fuel usage/milage/fuel cost since october 2012. Which is when I put the TDI Ranger on my run full time.
Its done monthly because no way I was going to input like 1000 fillups individually.
For some reason the spreadsheet wouldnt calculate properly unless I used a date after the current one. So 2016 = 2012, 2017 = 2013. So pretty much minus 4 years.

Lone Ranger · Feb 1, 2015

Gas Ranger mileage

And for comparison, here is my DOHC 2.3L gas ranger from the months before I started using my diesel one

JetJet · May 7, 2015

I have a question for you TDI guru's. I am assembling my 2002 Jetta TDI, new pistons, rods, top end rebuild. It blew the timing belt and damaged all the valves. I just finished installing all rods (because I discovered that 2 rods were bent) with good used ones I purchased here on the forum. I also purchase brand new pistons and what I discovered is that the pistons stick out over the block by just a bit. Approximately 1.10 MM
Is that normal? The head gasket is thick and I purchase the new and improved design. Please advice.

greengeeker · May 7, 2015

Hi jetjet. I would recommend you start your own thread on your rebuild and also invest in a repair manual for your car. To answer your question, yes it is normal to have the pistons protrude from the block - this is a critical dimension that must be in spec for all pistons so accuracy of your measurements is important.

JetJet · May 7, 2015

Thanks greengeeker, I have a manual however is turned out to be worthless.
But I'm looking for a shop manual that covers just my tdi year and model.

MÄDDNESSS · Apr 26, 2016

Sub'd to read later.

pilodriver · May 1, 2018

tdi ranger

are you still driving this truck?

Lone Ranger · Nov 29, 2018

pilodriver said:
are you still driving this truck?

Yes I surely am, but sadly the original motor the one with a mil plus lost oil pressure. So I put a new bullet in it in April and its back to hauling paper!

Never-Have-I-Ether · Mar 1, 2022

How's the truck going @Lone Ranger?

Lone Ranger said:
Yes I surely am, but sadly the original motor the one with a mil plus lost oil pressure. So I put a new bullet in it in April and its back to hauling paper!

Mongler98 · Mar 1, 2022

Never-Have-I-Ether said:
How's the truck going @Lone Ranger?

I'm not sure of we might hear from this user last seen In 2019.... 3 years ago. Sending this user a PM or Email might actually yield results.

Never-Have-I-Ether · Mar 1, 2022

Mongler98 said:
I'm not sure of we might hear from this user last seen In 2019.... 3 years ago. Sending this user a PM or Email might actually yield results.

Yeah, hoping it'll send him an email by me responding and bumping this thread.

Lone Ranger · Mar 19, 2022

No, I'm not driving that truck anymore. I built another one, my 3rd. The second one went to 1.35 million(altho not with the original ALH). After 7 years in our winters with these roads the body was done. So in may of 2020 I put another one on the road.
Its using the ECU from my last one with a stage 2 and a set of DLC 520s.
I reread some of this post and I should mention that the 2.3L clutch holds the 155ft/lb ALH. It does not hold the malone stage 2, 230ft/lb haha. So the only real difference between them all is the new one has the clutch/flywheel/pressure plate and starter from a 4L ranger

greengeeker · Mar 20, 2022

Lone Ranger said:
No, I'm not driving that truck anymore. I built another one, my 3rd. The second one went to 1.35 million(altho not with the original ALH). After 7 years in our winters with these roads the body was done. So in may of 2020 I put another one on the road.
Its using the ECU from my last one with a stage 2 and a set of DLC 520s.
I reread some of this post and I should mention that the 2.3L clutch holds the 155ft/lb ALH. It does not hold the malone stage 2, 230ft/lb haha. So the only real difference between them all is the new one has the clutch/flywheel/pressure plate and starter from a 4L ranger

And I can confirm the trans can't hold stage 4 torque

Lone Ranger · Mar 21, 2022

greengeeker said:
And I can confirm the trans can't hold stage 4 torque

haha stage 4! Whats that like 280ft/lbs? So what did it do to it? And was it the R1 or R2 M5OD

greengeeker · Mar 21, 2022

Probably right around there. Don't know what broke yet...assume it stripped the gears. M5OD-R1.

3baudios · Feb 4, 2023

Is there anything you can do to make one of those M5OD's a bit stronger? I am looking at getting a old ranger to put my ALH in as the MK4 body is a bit rusty and it is just in the drive waiting for something to be put into

Nozzleman · Feb 4, 2023

I am running an AX15 out of a Dodge Dakota with the 4.0 bellhousing and stock clutch with a Malone 4 and it has held up fine.

aryankee68 · Feb 12, 2023

3baudios said:
Is there anything you can do to make one of those M5OD's a bit stronger? I am looking at getting a old ranger to put my ALH in as the MK4 body is a bit rusty and it is just in the drive waiting for something to be put into

Why not just go with a Tremec T5 and never worry about the trans breaking ever again? If you've got that much power a T5 with V6 or V8 gear ratios shouldn't be an issue. I'm considering swapping the 5sp out of my 87 Ranger for T5 to make my build easier.

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