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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 October 31st, 2017, 06:45   #1
ManicMechanic
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Default Suzuki Samurai ALH swap

Hello. I thought I would put my latest project up for others to see. I'm putting a Volkswagen 1.9 turbo diesel in a 87 samurai. List of mods prior to engine swap are
YJ spring conversion
2 inch yj springs
Toyota axle up front
Rock assault Toyota rear axle
5.29 gears with a spool in the rear
Toyota power steering
OTR steering
4-1 gears in case
EOS t-case cradle
I was going to run the samurai trans with an acme adaptor but I don't think the 190mm clutch will handle the power and torque coming from the ALH. I found a 1984 Toyota Supra trans at the local junk yard and found it has a higher over drive than the same year truck trans and you can bolt a 22r bell housing right to it. When I looked at getting the adaptor from acme I noticed they don't use any dowel pins on either side and only 4 of the 5 bell housing bolts on the motor. Plus it costs 600 bucks. I figured I can do it better. So I did. Here's what the samurai looks like now and the adaptor. The adaptor use's all 5 bell housing bolts and the bottom 2 are dowel pins with threads in them to bolt from the engine toward the trans. I've been working on this for a while so I'll post up a bunch of pics as I can.


Last edited by ManicMechanic; February 25th, 2020 at 13:43. Reason: Spelling error
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Old October 31st, 2017, 08:40   #2
1.9ZOOK
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Nice
Did you dial indicate the runout? I had to do this to my homebuilt adaptor,then
drilled the dowel pin holes with tranny in place.Got it to within .004.
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Old October 31st, 2017, 10:42   #3
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I built a set of jigs to make sure it would come out strait. I haven't tried putting a dial indicator on it yet.




Last edited by ManicMechanic; February 26th, 2020 at 16:02.
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Old October 31st, 2017, 10:45   #4
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Old October 31st, 2017, 11:17   #5
1.9ZOOK
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I should have said ,drilled with the bellhousing and a "slice" of an old tranny to indicate off of.
You could do it with the front case of the r154(?) you have.Might be a little
tricky too get the indicator in there,but you have to do it so your clutch will last
longer than a 1000m.
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Old October 31st, 2017, 12:35   #6
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I'm getting the flywheel machined this week hopefully and I'll check it then. The transmission is a W58.
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Old November 1st, 2017, 01:25   #7
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Quote:
Originally Posted by 1.9ZOOK View Post
I should have said ,drilled with the bellhousing and a "slice" of an old tranny to indicate off of.
You could do it with the front case of the r154(?) you have.Might be a little
tricky too get the indicator in there,but you have to do it so your clutch will last
longer than a 1000m.
this^^ very critical as only about .005" off center will wear components and cause vibration
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Old November 1st, 2017, 01:26   #8
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Quote:
Originally Posted by 1.9ZOOK View Post
I should have said ,drilled with the bellhousing and a "slice" of an old tranny to indicate off of.
You could do it with the front case of the r154(?) you have.Might be a little
tricky too get the indicator in there,but you have to do it so your clutch will last
longer than a 1000m.
this^^ very critical as only about .005" off center will wear components and cause vibration
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Old November 1st, 2017, 04:54   #9
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Here are the motor mounts I made.




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Old November 1st, 2017, 08:39   #10
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Nice job on the mounts!
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Old November 1st, 2017, 08:54   #11
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Cool looking mounts. What vehicle are the rubber isolators from?

Are there any issues with mating the older Toyota truck t-case with the 2wd W58 trans?
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Old November 1st, 2017, 10:46   #12
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The isolators are from a Toyota 22r truck. I'm trying to use as many off the shelf parts as possible.
The T case is a samurai case not a Toyota. I used a larger flange with the Toyota flange on the case then made a really short jack shaft out of a toyota cv shaft.[IMG][/IMG]
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Old November 3rd, 2017, 18:13   #13
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I am digging this. I have an ALH in thinking about using for a conversion so this is very inspiring! keep up the good work!
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Old November 5th, 2017, 20:26   #14
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Reading through this is making me wish I could start mine, very nice work!! If you feel like you need to get rid of the motor mounts and the adapter plate then I’ll take them off your hands! But on a serious note, very nice work and I’ll be following because I hope to get mine started soon.


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Old November 6th, 2017, 12:53   #15
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Thanks. I think I'm going to need to hold on to the mounts. I might be able to make another set though. I think I would just use 1/4 plate instead of 3/8. 3/8s was over kill but it was what I had laying around. I need to check the plate run out before I go making any more adapters. I'll let you know if I make another one.
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