VAG 1.9 TDi into a RWD transit

[Luke]

not forgot about this but i've got the Tdi out - took it to work and given it a steam clean and today i've took the V4 out (well almost its just resting in place as i've nowhere to put it but its out in theory

[Luke]

no turning back now V4 engine is sold subject to collection

one empty engine bay

IMG_1943.JPG

[Luke]

Gearbox for anyone following this thread there are a few options for this, basically i have opted for a 2.0 crafter gearbox.

This wasn't the cheapest option and it has caused me a few problems but the reasons i went for it are:

its a new and quite common box so finding a replacement isnt going to be hard
it should bolt straight up (unfortunately it doesnt -read on)
it has a cable change so i can put the gearstick on the dash - mine being a camper this is a big bonus
i have a 4 speed fitted so even if i fit an MT75 i would have a lot of work to do
i like being different

if i was fitting this to a mk3/4/5 i would probably use an adapterplate and see if Tim AKA DIESELHEAD could sort me out a Tdi to Mt75 plate. if it was going in a mk6/7 i would proberbly do the same - the advantage of that is no need to make up mounts, tunnel, linkages and prop etc. but as mine is a mk1 all these i would need to do anyway

so ............. my box arrived today and i bolted it up to the engine but only on 2 bolts and no centring spigots - unfortunately the clutch is different and so is the flywheel and there seems to be an adapterplate in between the box and the block (hopefully that will line it up ok)- so i'm looking for one of those
but as soon as i can be sure it'll bolt up i'll get it in the van and get the mounts fabbed up

pics to follow

[Luke]

here's the engine and box 'sort of' bolted together

[oldyellar]

here's the engine and box 'sort of' bolted together

Getting there is it 6cog?

[Luke]

here's the engine and box 'sort of' bolted together

Getting there is it 6cog?

yeah it is - not sure of the ratios but i'll just see how it goes then adjust the back axle to suit

[Luke]

done a fair bit more but i cant get the pics off my sodding phone

had a go but couldn't get the engine and box in together - so ive split em and put the engine in (pics to follow) its not a bad fit - a bit tight to the drivers side as it is offset 27mm (all early transits are) i might have a few problems when i fit the PAS box but i'll cross that bridge when i come to it - i will need to raise the transmission tunnel so im after an MT75 floor piece from a mk3/4/5

this is the one from my other van



once thats in i think it will be ok - up front there is room for a rad but not much in front of the mechanical fan so i might have to get rid of that

[Luke]

pics from yesterday

[Luke]

today i got the gearbox bolted up it's now sat on blocks of wood to get the position right - it's very tight up front as i need to lift if to get the angle but it will be ok
hopefully the pump on the back of the head won't ever break as it'll be an engine out job

[andypdq]

hopefully the pump on the back of the head won't ever break as it'll be an engine out job

It's a VW, so no need to be paranoid.

Nice job, looking forward to seeing it in the flesh.

[Luke]

i'm hoping to get it to fordfair thats my target being realistic north weald aint gonna happen so i'll be there in the mk6

next big step will be getting it sat on some mounts at least then i can tow it about

[MinorMatt]

Why not bring the grey mk1/2 to weald?

[Luke]

Why not bring the grey mk1/2 to weald?

no tax test etc. plus its got all the Transitmania gear stored in it

[Luke]

done a bit more this afternoon (was raining all morning)

i've realised the crafter engine and the passat engine are set at different angles - with the crafter gearbox vertical the engine is about 10deg clockwise - there's no problem with that other than the engine mounts are at odd angles - i can't see 10 deg being a problem for the sump pickup and also it suits me to have a more vertical engine - the inlet is 5mm off the servo as it is (might have to change the inlet but i'll look into that later)

so i've decided to make new engine mounts using the passat rubbers make up some block mounts and mount them to the transit crossmember (being an early mk1 mine has this)

i've had to cut the centre out of the crossmember and weld in new metal as the front bowl sump is in the way - but it was easier to do this as i have loads of space under the engine

i do have some pics of the modded crossmember i shall see if i can add them from my phone - otherwise it will be later

[Luke]

sorry no pics still but i have the crossmember finished (well fully welded) got both block mounting plates done and bolted to the block - need to make some more plates up to the rubbers - going to do that tomorrow

ive measured up for a gearbox crossmember - decided to make the full thing from scratch rather than messing about adapting one

my aim is to get it sat on the finished mounts by the end of this week