BEW / 05 Ranger automatic swap

evguy1 · Apr 9, 2015

I had this stripped out 05 Ranger from when we converted it to electric power and then sold the electric drive system.
The Jeep build http://www.cherokeeforum.com/f46/2000-tdi-blacky-205238/ has gone so well that I decided to start on the Ranger and convert both side by side.
Both use the BEW engine.
The Ranger has a 5R44E automatic and the Jeep has the NV3550 standard.

Got the engine into the Ranger today and hopefully its in for good!

The Ranger will just be left stock other than a Malone stage 1.5 tune and a PD150 intake.
Is anyone selling those at a resonable price?

Here is the TDI block adapter in place.

Had to clearance the trans a bit for the starter drive.

A-man930 · Apr 9, 2015

Subscribing. You do clean work my man.

evguy1 · Apr 9, 2015

Thanks A-man. I have been doing EV conversions for 25 years.
When your playing with that kind of power it has to be clean!

Nozzleman · Apr 10, 2015

How are you going to control shift points on the transmission?

evguy1 · Apr 10, 2015

Not a clue. ;>)
On EV conversions I have had good luck keeping the stock Ranger ECU to run accessories and also have run automatics this way.
Usually just need a TPS and tack signal to run the ECU but each model and year is different so its trial and error, lots of error.

chucky2 · Apr 13, 2015

Subscribed. Man I'd kill for a work area like that!

Tagg33 · Apr 14, 2015

I'm subscribed. I really want to do a BEW swap in my 68 Jeepster and I want an auto trans. I'm super excited to hear how this goes for you.

evguy1 · Apr 14, 2015

Well it will go slow for a while. We sold some electric trucks this week so my projects will get booted out of the shop till those are built.
I'll try to get some time in on the weekends but that's usually pretty limited.

Nozzleman · Apr 16, 2015

Baumann Transmission controller?

http://becontrols.com/

Are you going to run VW accessories or Ranger?

evguy1 · Apr 16, 2015

VW accessories and I have a Baumann controller from another project that may work.

dcproven · Apr 20, 2015

This is a great idea, I wish it was easier in California to do this kind of thing...

evguy1 · May 22, 2015

Finally got some time to build the accessory drive relocation bracket.
It worked out real well with the alternator no higher than the valve cover but the PS pump up a lot higher to clear steering parts.

Nozzleman · May 31, 2015

Any updates? I have the donor car and I just bought my truck and am about ready to drop the hammer. I am going to run the 4.0 pattern for the bigger clutch.

For the record, a Ford 2.3 Duratec will weld solid 18 miles after the Quicky Lube forgets to put oil in it.

evguy1 · Jun 2, 2015

Yes, lots has happened just nothing worth posting about.
This truck had spent the last three years as one of our electric trucks.
We have spent the last few weeks putting all the gas parts back in like fuel tank and lines, cooling system, A/C system, exhaust system along with the PCM and all the engine wiring. Unfortunately we had a big cleanup about two years ago and all those parts went to the scrap yard.
Its been an adventure finding compatible parts as I think Ford changed the wiring layout every year.

This week we did get new exhaust and a fuel tank back in.
The rear axle has to be swapped for a stock one since the electric had 5:36 gears. Luckily that stock 4:11 axle is still here so its a quick swap.

cevans · Jun 2, 2015

What a cool project!

annieneff · Jun 2, 2015

Subscribed with high expectations of more of what you've shared so far. Did you rebuild that bew before you put it in there?

evguy1 · Jun 2, 2015

It only had 140,000km on it so it should give a lot more miles yet.
Once I get it running I'll do the cam and timing belt.
The turbo is off the BEW that's going into my Jeep which only had 57,000km on it.

Nozzleman · Jun 3, 2015

How much clearance did you end up with behind the vacuum pump? The adapter is 2 1/2" thick?

evguy1 · Jun 4, 2015

Ends up with about 1" clearance at the top of the pump. The adapter is 2" thick. The transmission was moved forward 2" and a driveshaft spacer added.

evguy1 · Jun 8, 2015

Got quite a bit done. Remote oil filter worked out well. Should be easy to change.
Got the rad and AC back in but will need to get some lines made up to mate the Ranger AC to the VW compressor.

Just waiting on a PD150 manifold to arrive from Germany. Hopefully late this week and then get this thing running.

chucky2 · Jun 9, 2015

Except for the oil filter bracket that looks like a factory install, man that's nice!

evguy1 · Jun 10, 2015

Shipment of manifolds arrived today so I could start intercooler piping.

DSCF3397

Intercooler just fits behind the grill.

Need to build a race pipe adapter for the manifold but otherwise it all fits.

evguy1 · Jun 17, 2015

Built a couple of race pipe adapters for the new intake manifold.
Sort of rough but not bad for a first attempt.

Installed, along with the modified cooling tube for the small return hose from the top of the head.

chucky2 · Jun 18, 2015

How close do you think you are to firing it up?

evguy1 · Jun 18, 2015

I was trying for this week but other work (paying work) keeps getting in the way.

I did get fuel lines installed and most of the rad/heater hoses installed today.
Just need to reprogram the ECM and it should be ready to go.
Hopefully early next week.
I'm not expecting it to actually move at that point since I don't have any of the chassis wiring and TCM hooked up but it will be nice to hear it run.

dokatim · Jun 20, 2015

how much of the ecm wiring are you keeping?

I am doing a swap right now and need some help figuring out what all I have to keep and what I can get rid of

evguy1 · Jun 20, 2015

What year Ranger is it?
Is it an automatic?
If its an older standard then you would need very little or none of the Ranger ECM.
We had converted this 05 to electric a few years ago and were able to totally remove the ECM but we had no transmission to control.
We were able to provide a signal to the tach through a Digital Dakota converter and everything else worked fine.

dokatim · Jun 21, 2015

I am doing the swap into a manual vanagon, I was speaking of the tdi ecu

evguy1 · Jun 21, 2015

Since I'm using a BEW it needs pretty much all the wiring.
To speed up this conversion I sent my harness to David @ http://www.fastforward.ca/ It came back ready to drop into the truck so it saved me tons of time!

dokatim · Jun 21, 2015

That is a huge help thank you

BEW / 05 Ranger automatic swap

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