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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 November 19th, 2016, 16:09   #61
1.9ZOOK
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You know now that you brought that up,I never thought about filling it.
Kind of too late now...will have go slow when fueling up.

The baffle closest to the filler neck has some good gaps so that's not a problem.
I can reach my hand through the sending unit hole with the plasma,I will cut
two 1 1/2" holes in the other baffle.

Last edited by 1.9ZOOK; November 19th, 2016 at 16:26.
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Old November 24th, 2016, 19:41   #62
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Nice work with the fuel tank mod! I modded my fuel cell pickup to pull fuel from the rear end of the fuel cell so that there would be no issues.I also keep my fuel cell full to avoid problems.I've yet to starve for fuel when running my buggy on its side or attempting to climb a steep grade.
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Old December 16th, 2016, 19:45   #63
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Thanx Andy,
yeah I would run out on obstacles like this when really laid over.

I don't plan on doing this with the diesel,more of a really capable camping
rig.
So way back when I was making the full circle adapter plate I made this statement
"How often does anyone take the oil pan off anyway" apparently when the diff makes
a hole in it.I had extreme death wobble because I forgot to swap out the blown steering
stabilizer(since replaced,no more bump steer)

So I cut out the hole and clearanced it.

...and rebuild the tranny,had over 200K on it and the added torque was to much for the worn bearings.
some tranny photos for entertainment only.




Wasn't as hard as I thought removing the tranny,in fact is easier than my `88 Toyota truck.
I was pleased to find no strange wear of any sort,pilot bushing,pressure plate,clutch all looked
good, so brought some piece of mind.
I have coated the fuel tank and it has dried for 3 days,goes back in tomorrow then test drive
again.
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Old March 21st, 2017, 18:54   #64
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Under the knife again...
I wanted the selectable locker cause the auto locker was way to squirrely in sloppy snow
conditions.
It was time to fab up the E-locker in the front axle,
Fortunately the locker came with the center housing making this chore easier.

Started by cutting out part of the face where the motor sticks out.
I had already modded the U-bolt and perch with welded in studs cause I knew the motor would be all over it.

Welded in the e-locker housing piece.
Had to trim a fraction of the modded perch

Pretty close but makes it.

Ready for some silicone and reassembly.

Added a gusset between the welded studs for a little extra support.

I also re-geared the rear to mach the front (4:10) At 25mph and 31" tires,2nd was over revving and 3rd was lugging,so now I can stay in 2nd.
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Old March 23rd, 2017, 17:51   #65
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Nice work Zook. Do you know how much your rig weighs?
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Old March 23rd, 2017, 18:16   #66
1.9ZOOK
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Thanks Moto
Haven't weighed it yet but I'm guessing around 3100.
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Old March 24th, 2017, 17:52   #67
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Didn't realize your build thread had so much good swap and fab porn! Nice work on the swap and the rig all around!
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Old March 24th, 2017, 20:11   #68
1.9ZOOK
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Thanx smelly621
Few more photos on the front locker...
Made a shaft to use with broken motor body so it can be manual.



Then made a lever to actuate it.

I have an old Samurai clutch cable and a 1/4" heim joint that will operate the locker,still have to figure out the handle.
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Old May 18th, 2017, 19:00   #69
1.9ZOOK
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A little update,after 500ish miles it started to get a little clutch chatter and a
slight bearing noise.I knew the alignment was probably out since I never indicated it.
So made a tool out of an old w56 tranny nose piece.

It was off .018 up and down and .008 side to side.
I made some offset dowels and it just wasn't happening,so I took the dowels out
,indicated with all the bolts snugged,got it within 1.5 thou.Tightened all bolts
and rechecked,nothing moved then drilled and pined in place.
Pretty happy now...




I'll get it back together this weekend and test.
Also received my VCDS yesterday so that will be interesting.
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Old June 8th, 2017, 14:52   #70
1.9ZOOK
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No more clutch shudder and everything is running smooth now.
Still haven't dug into the wiring yet but got some more fab work done.
Made some shift knobs and got the locker shifters and cables working,they
are effortless to lock and un-lock,so am happy about all that.



Photos of the lockers,still have to make rock guards for them.


And here's a video just for the heck of it...
https://www.youtube.com/watch?v=CEhh4DK6pPk
Thanx for lookin' Guys...
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Old June 8th, 2017, 20:16   #71
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Nice looks like fun.
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Old June 12th, 2017, 21:38   #72
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Looks super fun, and your manual locker conversion looks very nicely done as well. Jealous of your fabrication skills.

Those trails look fun - can you drop me a pm of where abouts you were? Would like to check them out next time I'm up your way.
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