Project: PolarXJ (M-TDI XJ)

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
2x the MPG, similar power with more torque, and being able or run WMO ... i love the 4.0, that YJ even has a stroker 4.6L, but it's hard to argue with this swap.

ok, it's louder and more vibratey, nothing's perfect.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
bumpers are DONE and on! i'm pretty happy with em. was a lot of work but learned how to finish metal better, and way better price. the front battery is just too easy for the receiver mount winch leads to reach too. needs a slightly lower back spacing wheel and 31s, but that's a next year issue. also need to make some rocker armor to cover where the old bumper used to.

Spartan locker in the back is 1000x better driving in the rain, i actually have the traction to accelerate now. found the worst over-use of RTV i've ever seen when i popped the diff :lol:





VERY nice job on the bumpers man!
I wish somebody made a kit like that for my 2nd Gen Ram.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
there are definitely DIY kits out there for a 2nd gen, I've even welded a set before for a buddy. they are just generally the huge bloated bumpers.
Yeah that’s the trouble. I’ve seen the Move kits and (just like every other bumper out there for these trucks), they stick out a mile in front. Disgusting.
Now I get that it has to be that way if you’re parking a winch behind it, but some of us don’t, and would prefer a nice slim bumper with a 2” receiver like yours above. Thuren makes a nice one, but it’s not a weld-it-yourself and it’s well over $2k.
Anyway, I’m done my rant. 😂
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
Yeah that’s the trouble. I’ve seen the Move kits and (just like every other bumper out there for these trucks), they stick out a mile in front. Disgusting.
Now I get that it has to be that way if you’re parking a winch behind it, but some of us don’t, and would prefer a nice slim bumper with a 2” receiver like yours above. Thuren makes a nice one, but it’s not a weld-it-yourself and it’s well over $2k.
Anyway, I’m done my rant. 😂
nothing wrong with a reasonable tangent!

Chassis Unlimited looks nice too, but again ... not a kit. i wonder if you call em and ask for a kit if they'd figure it out. less work, more margin usually.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
nothing wrong with a reasonable tangent!

Chassis Unlimited looks nice too, but again ... not a kit. i wonder if you call em and ask for a kit if they'd figure it out. less work, more margin usually.
That’s a good idea, I just sent them an email now. I do like the 4th Gen styled Octane series they have.
 

J_dude

Veteran Member
Joined
Jan 9, 2020
Location
SK Canada
TDI
2003 1.9l “Jedi”
No dice, they pretty much said well you can get it unpainted and that’s the best we’re going to do. And that they have free shipping so it’s already a very good price. Lol. Oh well.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I am planning on it, I'll be starting the build on the spring as i dont quite have a shop to work in over the winter.
Are you planning on the RADesigns set up where you manually shift the trans, an HGM controller or modifying the stock TCU?

Some newer aw4 TCU need a secondary speed sensors while other simply use a kick down cable and crank speed sensor. I'm not sure if any used a drive by wire, but that would be the best for a TDI swap
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
i feel like I'd try and leave all the factory ECU in place for the auto, i kept it just to run the gauges so it's already there. you'd still have the factory CPS and speed sensor ... but the TPS might need some figuring if needed.

i remember a switch mod back in the day to control the aw4 thru like 2 switches on/off
 

TDICherokee

Member
Joined
Oct 29, 2023
Location
British Columbia, Canada
TDI
2000 Jetta TDI + 2000 Jeep Cherokee
Are you planning on the RADesigns set up where you manually shift the trans, an HGM controller or modifying the stock TCU?
HGM Controller, they sell a kit that has an electrically controlled cable to take the place of the kick down cable, the other option is to get a Valve body out of an A340F (2007ish) Tacoma and have them program the controller to run the Toyota electric Solenoid. Both ways should work equally well.
 

TDICherokee

Member
Joined
Oct 29, 2023
Location
British Columbia, Canada
TDI
2000 Jetta TDI + 2000 Jeep Cherokee
i feel like I'd try and leave all the factory ECU in place for the auto, i kept it just to run the gauges so it's already there. you'd still have the factory CPS and speed sensor ... but the TPS might need some figuring if needed.

i remember a switch mod back in the day to control the aw4 thru like 2 switches on/off
Fast Forward Auto’s Harness included a Can To Dash Adaptor and VSS to Analog controller so if my assumptions are correct I can completely remove the Jeep Ecu and wiring harness the TCU doesnt talk to the Ecu except for throttle position. at all in the XJ/TJ, but the HGM is going to talk to the VW Ecu so minimizing the amount of wiring I have to keep under the hood will simplify the install
 
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PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
HGM Controller, they sell a kit that has an electrically controlled cable to take the place of the kick down cable, the other option is to get a Valve body out of an A340F (2007ish) Tacoma and have them program the controller to run the Toyota electric Solenoid. Both ways should work equally well.
Have you looked into converter stall? I'm having an issue finding out what the 4.0 converter stall was, some guess around 1800-2000 and I still haven't found what the TDI converter stall was. 1800 sounds right but I'm no slush box expert.
 

TDICherokee

Member
Joined
Oct 29, 2023
Location
British Columbia, Canada
TDI
2000 Jetta TDI + 2000 Jeep Cherokee
Have you looked into converter stall? I'm having an issue finding out what the 4.0 converter stall was, some guess around 1800-2000 and I still haven't found what the TDI converter stall was. 1800 sounds right but I'm no slush box expert.
Pretty much everything I’ve read is 1800-2200 for the 4.0 and I’d assume 1700-2000ish for the VW, but there are some wild claims that the TDI and 1.8T use the same converter which is 3000 stall. It’s close enough to or below torque peak with the factory 4.0 that I don’t really think it’s going to matter.
 
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PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
I hear ya on that haha it certainly would be less hassle but the Cost of a used ax-15 is basically the same as the controller and I wanna be different! 🤣🤣
I'm anticipating a successful swap. If the 6l80 doesn't work out an aw4 is the next transmission of choice for my current project.
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
so the little XJ is doing great, but still a few minor things. i think i need a new rear drive shaft, ya know, something actually balanced and not but weld extended by me.

i'm also having high EGT issues. i assume that's the mismatch of the Malone stage-3 and the 260 injectors. i really need to hit up burpod and just get a real tune going ...
 
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TDICherokee

Member
Joined
Oct 29, 2023
Location
British Columbia, Canada
TDI
2000 Jetta TDI + 2000 Jeep Cherokee
I'm anticipating a successful swap. If the 6l80 doesn't work out an aw4 is the next transmission of choice for my current project.
mines pretty basic, TDI swap, Iron rock front 3 link, JK d30/D44 (for now) 2” front stretch and 35s and let it eat till a break the front axle 🤣 6L80 1st gear would be nice but that 6th gear is so tall
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
You can't call it a jeep if you're not breaking parts and packing spares for every wheeling trip. Land Rover guys don't want to be the only ones needing a repair to limp back off the side of a trail.
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
build a front hipinion ford 9” for ****s n giggles
we recently built a junk yard 9-44 and i really want to build another. cut the knuckles off a ford d44 and a buddy machined them open to fit the 3" tube of the 9". junkyard factory 9" housing, welded the tube we cut off one side back onto the other to make it long enough. as part of the links it'll be trussed, so no worries there. built to 60" wms. the housing with knuckles is SOOO much lighter than a bare fabb'd 9. only oddity is having to grind down the tube weld seam to fit the inner axle seal housings, and they'll need RTV'd in.

a while back i had a bunch of the pucks made for the rod-style axle jig and slowly had other ends machined. d44 and d60/14b spindle threads, basically any end up bearing now, works awesome.
 

PickleRick

Veteran Member
Joined
Nov 29, 2017
Location
Greenville sc
TDI
05 GLS BHW sedan 5 speed conversion. BHW Carver SantaCruz in progress
You guys are pretty hard core, I still rock ifs unlocked on 285s. CV axles are cheap and can be swapped with hand tools and an jack!
 

TDICherokee

Member
Joined
Oct 29, 2023
Location
British Columbia, Canada
TDI
2000 Jetta TDI + 2000 Jeep Cherokee
we recently built a junk yard 9-44 and i really want to build another. cut the knuckles off a ford d44 and a buddy machined them open to fit the 3" tube of the 9". junkyard factory 9" housing, welded the tube we cut off one side back onto the other to make it long enough. as part of the links it'll be trussed, so no worries there. built to 60" wms. the housing with knuckles is SOOO much lighter than a bare fabb'd 9. only oddity is having to grind down the tube weld seam to fit the inner axle seal housings, and they'll need RTV'd in.

a while back i had a bunch of the pucks made for the rod-style axle jig and slowly had other ends machined. d44 and d60/14b spindle threads, basically any end up bearing now, works awesome.
this Is awesome that some body has done it! , my plan is to get a Currie or Ruffstuff 9” housing and Use Currie JK inner Cs so that beyond inner axles shafts everything is JK so I can keep my Method Bead grip wheels, I’ll probably go coil-over in the front at that point.
 
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