Toyota Tacoma ALH Swaparoo!!

Mykl8

Veteran Member
Joined
May 5, 2011
Location
Qualicum Beach B.C.
TDI
2000 Golf TDI 5spd, 2003 Golf TDI 5spd
Hi Jimbote, I'm hoping to get started on a BHW swap into my 04 Tacoma this winter. A big concern I have is the diff to oil pan clearance. I saw the notch you made in the pan but the other pics of what I think of it being installed don't work because of the whole photobucket fiasco. Any chance you could repost them?
Just another option, I did a 2" body lift on my swap to gain diff to hood clearance. Might be an option :)
 

Reh5108

New member
Joined
Sep 18, 2017
Location
Colorado
TDI
None yet
Just another option, I did a 2" body lift on my swap to gain diff to hood clearance. Might be an option :)
I'll probably do a1" BL but don't want to go more than that. I'd like my center of gravity to stay close to where it's at already and I'm not sure how well the extra leverage on the mounts would hold up to heavy offroading.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
AC eliminator bracket redo


been running a cheap dorman ac eliminator for an mk3 but lately the crappy little bearing has been making noise, it's cast into the plastic pulley so basically non serviceable... so i dug through my stash of AC compressors and found a suspect unit... gut it n' cut it !


backside showing the now angle cut piston bores... this bearing should last a looong time... the reason i chopped it down is the compressor as a whole runs really close to the taco cross member... this gives it plenty of room and is easier to remove/install
 
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Motohead1

Veteran Member
Joined
Jul 16, 2016
Location
charlotte
TDI
2002 bug+telephone pole
Nice. I dont have an eliminator and just have the stock ALH compressor hanging out to keep a stock belt. I might have a little more room than you have. I though about doing somthing similar until I found a thread on how to convert a sanden compressor to run on grease so it can be used as an onboard air compressor. If it dosent work I like your band saw solution for a good high mile bearing.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Nice. I dont have an eliminator and just have the stock ALH compressor hanging out to keep a stock belt. I might have a little more room than you have. I though about doing somthing similar until I found a thread on how to convert a sanden compressor to run on grease so it can be used as an onboard air compressor. If it dosent work I like your band saw solution for a good high mile bearing.
can you share that link? my buddy is building aluminum bumpers and the front is doubling as an air tank
I love stuff like that!
junkyard dog !
 

Motohead1

Veteran Member
Joined
Jul 16, 2016
Location
charlotte
TDI
2002 bug+telephone pole
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1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Dunsmuir,Ca.
TDI
ALH Samurai
I've been using a GM compressor for many years,but they are sort of bulky, that sankyo looks a bit slimmer and a little more rugged..
 

vtpsd

Veteran Member
Joined
Aug 15, 2013
Location
Vermont
TDI
03 jsw TDI, audi 90 AHU swap
Hi Jim,

What is your current clutch setup, and is it holding? I know you were on a 10" 5vze disk and PP with an upgraded pressure plate, but i see a reference to that setup slipping as well.

Trying to collect parts for my setup, and am trying to figure out the best direction to proceed. The 10" v6 setup seems like a great place to start.

I believe you are now on a tuned bv43 turbo setup? Is it safe to say that the ACT t020 pressure plate and dtx-136 disk will hold a 1.9 ALH with stock BHW turbo on it?

I wonder how something like this would work behind a TDI.
https://www.urdusa.com/competition-clutch-stage-ii-5vz-fe/

Again, thanks for cataloging all your progress along the way.
 
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jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Hi Jim,

What is your current clutch setup, and is it holding? I know you were on a 10" 5vze disk and PP with an upgraded pressure plate, but i see a reference to that setup slipping as well.

Trying to collect parts for me setup, and am trying to figure out the best direction to proceed. The 10" v6 setup seems like a great place to start.

I believe you are now on a tuned bv43 turbo setup? Is it safe to say that the ACT t020 pressure plate and dtx-136 pressure plate will hold a 1.9 ALH with stock BHW turbo on it?

I wonder how something like this would work behind a TDI.
https://www.urdusa.com/competition-clutch-stage-ii-5vz-fe/

Again, thanks for cataloging all your progress along the way.
hey Vtp... i had the t020 pressure plate and my foot hurt after about ten minutes of driving...i pulled it and reinstalled the stock aisin PP... i would go with ctx107 and a disc with modified/hybrid friction material such as kevlar/sintered combo ..the ACT is brutally hard to push, i'm a fit 6ft 210lb dude and it was unbearable for a daily, not to mention it would certainly cause early failure on upstream components
 

vtpsd

Veteran Member
Joined
Aug 15, 2013
Location
Vermont
TDI
03 jsw TDI, audi 90 AHU swap
Wow, glad I asked. Good to know.

I wonder if the Competition clutch that I linked would be a good choice. It does say that the pressure plate is modified, so maybe it would be the same problem as the ACT PP.

Do you know where a disk like that could be purchased by itself?

I also wonder if its worth a call to southbend. I have found them to be knowledgeable and willing to help with somewhat custom applications. They may be able to assemble something that would work well.
 
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jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Wow, glad I asked. Good to know.

I wonder if the Competition clutch that I linked would be a good choice. It does say that the pressure plate is modified, so maybe it would be the same problem as the ACT PP.

Do you know where a disk like that could be purchased by itself?

I also wonder if its worth a call to southbend. I have found them to be knowledgeable and willing to help with somewhat custom applications. They may be able to assemble something that would work well.
Southbend might be a better choice for a clutch disc if built from all new parts, I had them modify a stock new DTX 136 and I was not happy with the results, still have not installed it
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
drama free update and steering wheel upgrade :)

been awhile since I've had news to report on the swap but over 165k miles since "completed" ....i did have an injection pump failure that left me dead in the water @ bank drive through... just normal maintenance items and a few upgrades that include; rear four leaf HD springs, tundra TRD 4x4 front coils and tundra bilstein 5100's, and a matrix/celica wheel upgrade ..love this one! my old wheel was from a third gen 4runner and the leather was starting to degrade and come unseamed so i picked up a matrix wheel and celica bag. Not a straightforward swap but doable in an hour. Had to cut and splice the celica airbag connector to my taco clockspring and modify the lower horn contact (i only have side to side horn now)... wheel is slightly smaller diameter with fatter ovalized cross section on the ring...but best of all? it's a three spoke! :D




dirty daily ;)
 
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jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI


small update... around 175k miles so far, upgraded the chra to a BV43A unit, and installed an ARB front bumper after giving up on the aluminum bumper project... trail gear rear going on tomorrow. ;)

one interesting thing of note; after installing the relatively hefty front bumper/winch combo the in cab vibes from the diesel are diminished by over 50% ... acts like a weighted vibration dampener ;)
 
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Motohead1

Veteran Member
Joined
Jul 16, 2016
Location
charlotte
TDI
2002 bug+telephone pole
How high are you boosting the bv43a? I love mine on the low end but loaded or up top leaves me wanting to finish the compound setup parts I have laying around.



Good to know on the bumper dampening the vibes. Bonus!
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
How high are you boosting the bv43a? I love mine on the low end but loaded or up top leaves me wanting to finish the compound setup parts I have laying around.



Good to know on the bumper dampening the vibes. Bonus!
tune is set for 24psi... honestly the BV43A turbo feels a little better down low but not as good lit up as the BV43B.
 

tims944

Veteran Member
Joined
Jan 8, 2019
Location
montreal quebec
TDI
2006 mk5 tdi, 1989 944 s2 BHW swapped
tune is set for 24psi... honestly the BV43A turbo feels a little better down low but not as good lit up as the BV43B.
Mind if i ask your opinion on a bv43? i have a fresh rebuilt bv43 i put on my bhw, it cost me next to nothing especially after i sold my original 1749...
and it was rebuilt in germany not china...

i would imagine it has the cast compressor and turbine never really noticed but it worked perfect for my setup in terms of entry and exit
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
Mind if i ask your opinion on a bv43? i have a fresh rebuilt bv43 i put on my bhw, it cost me next to nothing especially after i sold my original 1749...
and it was rebuilt in germany not china...
i would imagine it has the cast compressor and turbine never really noticed but it worked perfect for my setup in terms of entry and exit
.
great turbo, tiny bit of lag but moves a good bit of air.
 

jimbote

Certified Volkswagen Nut
Joined
Jul 10, 2006
Location
spiral arm, milky way (aka central NC)
TDI
Tacoma 4x4 converted to TDI
just posted a TON of pics on my media bank.... two sections, one for this thread and one for the BHW/ALH hybrid. They are not in order but I may address that in the near future by cleaning up the broken photobucket links and replacing with the TDIclub hosted pics.
 

1.9ZOOK

Veteran Member
Joined
Dec 13, 2015
Location
Dunsmuir,Ca.
TDI
ALH Samurai
just posted a TON of pics on my media bank.... two sections, one for this thread and one for the BHW/ALH hybrid. They are not in order but I may address that in the near future by cleaning up the broken photobucket links and replacing with the TDIclub hosted pics.
I gave trying to re-photo all the pics on my build after photobucket screwed everyone ,too maddening!
 
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