Welp, it looks like I'm starting over. Truck got destroyed.

Nozzleman

Veteran Member
Joined
May 30, 2014
Location
About 15 miles from Venus
TDI
2002 Ford Ranger ALH
I recently loaned my 2002 Ranger TDI conversion to my son because all of his stuff was out of service. He was headed westbound on a 60 mph 2 lane and ended up going in the ditch and rolling it 4 times to avoid a head on with an eastbound who decided to pass another eastbound in spite of it being a no passing zone and there being oncoming traffic. Son crawled out of where the back glass once had been and dusted himself off and had only soreness and a bit of seatbelt rash.

God is good!

The driver that caused the accident didn't even bother to stop and check if he had killed anyone. Dashcam does not appear to have been able to capture the license plate. I might release the video when DPS gives up assuming they are even trying to investigate. All USAA had to say is "too bad." In Texas, if you don't make contact, uninsured doesn't cover.

Anyhow there is not a straight piece of metal left but the drivetrain did survive. The engine had the better part of 300K on it and is due a timing belt and a needs a cam at minimum. I had talked to Frank previously about one of his cams and porting the head. Might as well upgrade turbo while we are doing that. With a Malone 4 tune, VNT17, 11mm pump and the injectors that are in it, I am pushing the safe limits of the stock rods, so I am told. That figures up to somewhere around $2K+ in parts.

I bought another 2002 Ranger so that if I decide to recreate the truck, it is pretty much plug and play with minimal work.

So the question is: Do I keep on with the ALH building on its stock 90 hp rating or go to a BRM, CBEA or CJAA and build from there?

I welcome your thoughts.
 

GlowBugTDI

Veteran Member
Joined
Jul 20, 2018
Location
Cambridge, MN
TDI
2001 Beetle GLS TDI (BIODSL). 01 original Glow Bug TDI (sold)
I agree with greengeeker.
CJAA would be cool, but it will cost you a LOT more to buy that car (probably a wreck) and build/tune/delete from there then it would to just build the ALH. Not to mention the time it would consume (but what's that anyway when your having fun building;)), that you could use driving around in your built alh ranger. You would have to mostly reconfigure the entire build. Though as cjaa's are getting cheaper to find I will be excited for the builds that start popping up!

Glad to hear that your son is well though! That could have ended a lot worse and I'm glad it didn't.
 

6_DoF

Veteran Member
Joined
Sep 23, 2022
Location
Black n Gold Territory
TDI
1.9 ALH XJ
holy crap! glad he's ok!

sux about the rig / insurance ... maybe try Hagerty with an agreed value?

lots you can do with the ALH, already have it, etc. i'm another vote to keep it.

truck carnage pics?
 

Alberta 7.3

Well-known member
Joined
Nov 11, 2017
Location
Calgary, Alberta, Canada
TDI
CBEA Ranger under construction
Good to hear your son came out of it with only some scratches, Rangers are surprisingly tough little trucks, I hit a deer a month or so ago with only some dings to the fender and door.

Any upgrade to a different engine would depend on how much you want to spend and the time involved to adapt any parts that would change to suit the new powerplant. I'm doing a CBEA since I found a complete car for relatively low cost, my choice was to get a Passat BHW, but they are getting hard to find in my area. Once you change from a ALH to a PD or CR engine, the wiring gets a bit more complicated, and you'd have to buy a new tune for it as well to get rid of the immo and other unneeded stuff, adding to the cost of the swap
 

dhangejr

Veteran Member
Joined
Mar 1, 2017
Location
PNW is my home
TDI
mk4 Jetta
I’d get a cheap CJAA if I had the money but they are gonna cost a lot more.

ALH is pretty a solid engine, with less problems then the CJAA and it has been better tested fo mods.

mid your nearWA check out my FS thread I’ve got a pretty sweet1.9 wagon I’m just a Ii over it ;)
 

Alberta 7.3

Well-known member
Joined
Nov 11, 2017
Location
Calgary, Alberta, Canada
TDI
CBEA Ranger under construction
Did you ever do a build thread for this rig? I have questions.

I'm guessing you used 2.3 A/C lines and compressor to have the compressor on the right side of the engine, to avoid the one refrigerant line running over the front of the engine. I've bought the 2.3 parts and am doing the same setup.

The one photo has the 2.3 coolant degas bottle and washer fluid reservoir (which would be used with the 2.3 rad sans cap) but the current photo has the 3.0/4.0 reserviors. What was the reason for change?
 

Nozzleman

Veteran Member
Joined
May 30, 2014
Location
About 15 miles from Venus
TDI
2002 Ford Ranger ALH
No I never did a build thread on this truck. Long story short, I spent a bunch of time doing one on another site back before build threads became a thing and the site didn't approve of it and deleted it. Can't be putting a Cummins in a Ford. That's crazy talk! Oh well....

The Ranger I started with was a 2002 XLT 2.3 5spd with a hole in both sides of the block that a guinea pig could walk through. Apparently these engines will run 18 miles after the quickee lube forgets to put oil in it until it starts knocking and then puts some in before it hangs a rod through the block. High miles, nice body, blown engine=cheap.

I used a ~98 style Ranger 4.0 radiator and bottles from a 95-99 Explorer just due to the difficulty plumbing it with the 2002 Ranger setup and the fact that the original radiator wasn't very sound.

I built mounts to run the existing compressor and lines and never even opened the system.

The XLT has the metal low riser hood and wouldn't clear the intake so I put an "Edge" fiberglass hood and grill on it . The PD150 intake still rubs the insulation blanket but hasn't damaged it much in 60K miles since build. The XLT grill will work with the Edge hood but the nose contour is a bit different.

The truck I bought to replace this one (if I do end up converting it) is an Edge which has torsion bars instead of the coil springs like the XLT had. That deletes the big cross member under the pan and it appears that it will make an cleaner swap. Almost makes me wonder if I could run the VW alternator and compressor.

I might end up doing a build thread on the rebuild.

Let me know if you have any other questions.
 

Alberta 7.3

Well-known member
Joined
Nov 11, 2017
Location
Calgary, Alberta, Canada
TDI
CBEA Ranger under construction
Cool, thanks for the answers. The Edge model "powerdome" fiberglass hood was Ford's answer to get the 4.0 SOHC to fit, later models all got a slightly domed steel hood. I'm replacing my 08 steel hood with a modified Edge fiberglass hood anyway to avoid a rust issue (modified the front lip to match the 04 and later grille shape.)

I'm still on the fence with which radiator and reservoir to use, my 3.0/4.0 rad has an angled side tank from collision damage which will get replaced anyway. My plumbing will likely be different anyway since I'm swapping in a CBEA.
 

chucky2

Well-known member
Joined
Mar 11, 2010
Location
Chicagoland, IL USA
TDI
Ford Ranger FX4 Level II
Isn't it easier to ship things like engines/transmissions internationally now? I thought I had read that a long while back...if so I wonder if it'd be possible to get a 4cyl TDI and even trans/trans+transfer case from overseas in a longitudanal layout.
 

Nozzleman

Veteran Member
Joined
May 30, 2014
Location
About 15 miles from Venus
TDI
2002 Ford Ranger ALH
I bought a 2005 Ranger Edge in April or May that a guy had tried to put a 4.6 Modular engine in and gave up when the engine hit the upper control arm mounts after its PO blew up the 3.0. It was last licensed in 2015. "I promise I will have you the title but I can't find it right now." So I got to learn about Bonded Titles...

I just got the truck on the road and it has about 100 miles so far so I am still ironing out little bugs but nothing major.

The wiring harness is a lot different in between 02 and 05 so after looking at it briefly, I just jerked out the entire harness and swapped in the one that was already integrated with the TDI.

The old truck was a coil spring XLT and the new one is torsion bar front suspension. The pan was close to the front cross member previously and was close enough to the top of the rack that it polished it over the 90K that I drove it. The intake ran close enough to the hood to damage the insulation. The taller hood(?) and lack of the cross member improved everything fit-wise. The distance between the top of the engine mount and the top of the fender is greater on the torsion bar truck so the engine height is not an issue any more. I don't even have to put a sheet of metal on the cross member when I drain the oil now. I did have to rework one engine mount but it wasn't a big deal.

Knowing what I now know after building 2 of these things, I would be looking for a torsion bar truck for a swap candidate.
 

Alberta 7.3

Well-known member
Joined
Nov 11, 2017
Location
Calgary, Alberta, Canada
TDI
CBEA Ranger under construction
Yes, the 02 and 05 have radically different wiring. The 05 has much more CAN stuff and less individual modules. My 08 is going to be some sort of hybrid turd sandwich of electrical harnesses.
 
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