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Fri May 27, 2022 9:08 am

You can use the DMF with the stock vanagon diesel bell housing and the AHU TDI. The parts for install are readily available and relatively inexpensive.

You cannot use the DMF with the Boxeer kit or any other adapter plate installation. The Boxeer kit mounts the engine at 15° so there is not any available bell housing or adapter plate that will work with the DMF for that install angle.

The FAS TDI install kits also use an adapter plate and do not come with the DMF. Those are installed at 50°, though, and it may be possible to replace the FAS adapter plate and clutch setup with the stock diesel vanagon bell housing and install the DMF although I have not done so personally and do not yet know of anyone who has.

I do not know what a PDK install would cost. Probably more than the engine conversion.

Fri May 27, 2022 9:11 am

Sodo wrote: How much does 'the stuff' cost.....to install a Dual Mass Flywheel?
Are there enough DMF parts out there for everyone who wants it?

PDK sounds exclusive and expensive.
How much would it cost to get a PDK?
I'm thinking that there won't be more than 5 PDK-vans in the whole world.
And it will be awhile before we know how far it can push the brick.
We'll never know if these 5 vans are garage queens.

I have inquired about the PDK. Right now, it looks like it needs to be 'tuned' and 'tested' to the van. So a trip to his shop is required (install fee).

For the whole package (Engine, Transmission, Front Diff, Driveshaft?, CV's? all the odds and ends)- $32k.

But, I'm hopeful as time passes, DIY options will become available.

Fri May 27, 2022 10:35 am

wasatch wrote: Sodo wrote: How much does 'the stuff' cost.....to install a Dual Mass Flywheel?
Are there enough DMF parts out there for everyone who wants it?

PDK sounds exclusive and expensive.
How much would it cost to get a PDK?
I'm thinking that there won't be more than 5 PDK-vans in the whole world.
And it will be awhile before we know how far it can push the brick.
We'll never know if these 5 vans are garage queens.

I have inquired about the PDK. Right now, it looks like it needs to be 'tuned' and 'tested' to the van. So a trip to his shop is required (install fee).

For the whole package (Engine, Transmission, Front Diff, Driveshaft?, CV's? all the odds and ends)- $32k.

But, I'm hopeful as time passes, DIY options will become available.

That's a lot of money, yet at the same time you are getting a total AWD drive train that's up to date and very hardy. (New van really) Seams like the last money you would throw at a van because your replacing all the problem areas at one time.

I have always seen the Vanagon as a shell to create what you want and need. There is nothing like it out there, so if you can afford it, Roll Out with your Goals Out. :lol:

Fri May 27, 2022 11:29 am

chrismsnt wrote: Thanks for acknowledging and agreeing to pay for shipping. 😂

500+ shipping on top I might still be interested :wink:

Fri May 27, 2022 11:38 am

To supply the Vanagon market, you need donors that are strewn about like spent condoms.
Subarus, Jettas, Fords.
What vehicle offers the PDK gearbox and all its accoutrements?
How many are there (usable)?&
How long do they last and how rebuildable are they?
Can you install a 90,000 mile unit from the junkyard?
Or do you have to buy the complete vehicle?
Did that PDK’s “first owners” comply with the mfr, never replacing lubricants too?

If it takes $32,000 ya gotta compare that to $10k for a 100%new gears, shafts, case VW gearbox and just drive 65-70mph and “maintain it”. Vanagon gearboxes last towards 200k with poor maintenance. How about not pushing it too hard, and maintaining it from “new”?

Most peoples experience with Vanagon gearbox troubles is “3rd owner” slapping on a huge engine and starting a maintenance program after its whining & putting out big fuzzy magnets.

Fri May 27, 2022 12:29 pm

Sodo wrote: Vanagon gearboxes last towards 200k with zero maintenance. How about not pushing it too hard, and maintaining it?

The extra fuel cost, total drivability, and reliability comes into play here. Yes, a Vanagon trans box can drive along time when doing 55 mph without hills. Yet, I'm sure there are a lot of people that want to enjoy there Vanagon wail not causing traffic slowdowns due to underperforming vehicle on the freeway. Stock is not for me, but others may enjoy it.

In the end there is no wrong answer, its about what you want and are willing to except from a vans performance.

Fri May 27, 2022 2:28 pm

Ten is just about untenable.

(Regarding $10,000 rebuilds)

Mon May 30, 2022 12:45 pm

Greg / Boxeer does come on the Samba. Check out his question just today in this topic

https://www.thesamba.com/vw/forum/viewtopic.php?p=9867243#9867243

Tue May 31, 2022 2:47 pm

Jjaramillo wrote: Hi. I am just going to install the boxeer kit in a sycro with Jx 1.6 td Diesel engine. Those that already have I installed the kit where is the cooler for the intercooler location that you are using. ?

only real place to install the interooler is up front in front of the rad on the exterior of the van. Folks have had real mixed success in other spots- though with that said, if youre good with active fans on the intercooler, you could probably mount anywhere

Wed Jun 01, 2022 1:36 pm

charleslabri wrote: Jjaramillo wrote: Hi. I am just going to install the boxeer kit in a sycro with Jx 1.6 td Diesel engine. Those that already have I installed the kit where is the cooler for the intercooler location that you are using. ?

only real place to install the interooler is up front in front of the rad on the exterior of the van. Folks have had real mixed success in other spots- though with that said, if youre good with active fans on the intercooler, you could probably mount anywhere

Interesting video at Greg's shop discussing putting the intercooler inside an aftermarket skidplate with appropriate duct work to exhaust the ram air or additional fans. Intercooler talk begins at 15:15.

Intercooler talk begins at 15:15.

Mon Dec 12, 2022 5:54 am

Hello to response about Boxeer conversion details on 82 Westfalia. Been up and running for one year. Brake problems without being solved because of possible booster, although I’ve tested vacuum and has held. Was told by a good mechanic that there may be too much vacuum. This kit was designed for water cooled engines which have a different mounting distance than air cooled. I had a choice of adding spacers at rear mounts supplied with Boxeer kit or modify transaxle mount and shift linkage.I did the latter deal. Boxeer said along with Steedle that shouldn’t be an issue. I have harmonic vibration under load in 50-55mph range. Was told by other air cooled conversion customers it’s because injectors are not coded. Now experiencing hard shifting into second gear. Linkage is all good with hot shot shifter. This came on slowly with grinding when going in reverse after warmed up. So brakes, vibration and shifting are clouding my conversion after 14K mileage. Basically zero support from Boxeer. Steedle says shifting problem is faulty clutch not synchronization. He did rebuild. Vibration? Brakes? I know input shaft was shorter required for conversion. Clutch assembly is very noisy in neutral. Again a typical complaint. Thoughts?

Mon Dec 12, 2022 7:06 am

italianman53 wrote: Hello to response about Boxeer conversion details on 82 Westfalia. Been up and running for one year. Brake problems without being solved because of possible booster, although I’ve tested vacuum and has held. Was told by a good mechanic that there may be too much vacuum. This kit was designed for water cooled engines which have a different mounting distance than air cooled. I had a choice of adding spacers at rear mounts supplied with Boxeer kit or modify transaxle mount and shift linkage.I did the latter deal. Boxeer said along with Steedle that shouldn’t be an issue. I have harmonic vibration under load in 50-55mph range. Was told by other air cooled conversion customers it’s because injectors are not coded. Now experiencing hard shifting into second gear. Linkage is all good with hot shot shifter. This came on slowly with grinding when going in reverse after warmed up. So brakes, vibration and shifting are clouding my conversion after 14K mileage. Basically zero support from Boxeer. Steedle says shifting problem is faulty clutch not synchronization. He did rebuild. Vibration? Brakes? I know input shaft was shorter required for conversion. Clutch assembly is very noisy in neutral. Again a typical complaint. Thoughts?

Your shifting issues definitely sound like a clutch not fully disengaging. If it will shift into gears smoothly when the engine is not running but grinds going into gear when the engine is running is a major clue.

Mon Dec 12, 2022 8:13 am

symptom of sticky pilot bearing too.

Mon Dec 12, 2022 8:53 am

danfromsyr wrote: symptom of sticky pilot bearing too.

Good one. Yes.

Mon Dec 12, 2022 9:42 am

italianman53 wrote: Basically zero support from Boxeer.

This is the sentence that relates to this topic title...and its a shame.

Greg could really have a great enterprise if he solves this issue which is totally within his control.

Mon Dec 12, 2022 1:19 pm

the dude a 5;47 has a 10 bullets tattoo. id hire him for whatever an hour he asked for. thats cool.

Wed Dec 14, 2022 10:16 am

vanis13 wrote: italianman53 wrote: Basically zero support from Boxeer.

This is the sentence that relates to this topic title...and its a shame.

Greg could really have a great enterprise if he solves this issue which is totally within his control.

I haven't found that to be true. Greg has helped the best he can with issues encountered on my install. Its by text and email and sometimes not right away, yet he has tried to address the issues when he responds.

Wed Dec 14, 2022 10:52 am

vanis13 wrote: Greg could really have a great enterprise if he solves this issue which is totally within his control.

Not necessarily.
Creators are often not 'people persons'.
Now we're requiring a team of at least two.
Then there's the employees who will do the work day in / day out.
More employees.
The work is organized for them by someone who has that skill too, perhaps yet another employee.

Business is not just easy nor obvious.

Wed Dec 14, 2022 11:26 am

If the engine is using the stock ECU, you should be able to code the injectors with VCDS software and a dongle. Can’t imagine traveling without a laptop configured to connect.

Sounds like you reused the 091 transaxle. I built our conversion on our 82 around the same transaxle. Ended up with a later 091/1. I had to modify the trans mount to allow the trans to be forward so I could leave my engine mounts in their location. Sort of the opposite problem you had.

Know that the CV shaft length is different between the 091 and 091/1 transaxle that came in the WBX. In other words, you need to verify your CV shafts are correct and not binding.

My ALH is smooth to about 3600 in lower gears. If I redline it through the gears the shift lever buzzes some. No vibration in my butt. I’m geared for about 3200 at 70 mph and it’s very smooth on the highway. Like a new car. So, there is something to check.

It would be a difficult business to offer “kits” to a range of different skilled folks. Plus the EPA has been cracking down on modifying vehicles. Good luck sorting it out.

Wed Dec 14, 2022 5:07 pm

Hello, Matt Steedle rebuilt my unit. He also said the transaxle should be fine setting back 1-7/8” because these kits were not designed for air cooled setup.
The vibration is harmonic. Have had it ever since I installed TDI. Had problems with the ECU back in March. Went into limp mode. Shipped it back to Boxeer & they claimed it got fried and I would pay $450 for new unit. I had a certified mechanic who has tuned vehicles for a living. I said I’m not paying cause it was running fine when shut down. Mechanic basically hung up on Greg Blachon trying to have a conversation about why are there sensors that need to be disconnected. MAP, exhaust temp, fuel temp. I spent a lot of time and money with no real support. Skills? I’d say I’ve racked a few over the past few years. Especially with finding a network of folks that have done these conversions and have been programming there own ECU and gotten some pretty incredible improvements on how these Boxeer units perform. I’ve tried to get some simple feedback since I bought the kit in 2020. Got a great sales pitch when I made the payment. The clutch problem was verified by Steedle. No way it’s synchronizers.
Sorry I’m frustrated with the whole deal. Like a response I got from someone out west who had the same harmonic vibration,
Saying you got it running, now all the quirks are coming your way. I appreciate the feedback from all. Someone said they wanted some from installers.