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soissisc
Samba Member
Joined: April 04, 2007
Posts: 756
Location: Western Pennsylvania
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 Posted: Thu Jul 17, 2025 7:20 am Post subject: Re: ABA Vanagon Conversion |
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There should be a little window where you can get to the flex plate bolts (or nuts) one at a time once the trans is mated to the engine.
This is from my eurovan, but something similar. There is a little cover plate held on with a couple of small bolts. I didn't know if the adapter plate has a spot for this or if you'll need to break out the grinder again?
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Mark
68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up) |
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MarkWard
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Joined: February 09, 2005
Posts: 18824
Location: Retired South Florida
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| Posted: Thu Jul 17, 2025 7:31 am Post subject: Re: ABA Vanagon Conversion |
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Does the adapter plate have an access hole for installing the flex plate bolts after mated? You will need this access.
A few tips. When installing the torque converter a gentle turning action helps it seat completely. You should feel each step as it slips in.
Align the engine flex plate with your bolt access hole. Visually set the torque converter so that one of the threaded bosses will line up with the flex plate bolt hole. A tie rap thru the torque converter to the bell housing will hold it in place.
To know you have the torque converter properly seated, bolted to the engine, the torque converter should spin freely before you attach the flex plate bolts. If not, something is not correct.
Last, if your clearance is good, install all 3 bolts hand tight. Then torque them down. I use blue Loctite on the bolts as a precaution. I believe VW recommends replacing them, but I’m not sure. I’ve successfully reused them.
One last thought. It’s a good idea to prefill the torque converter. Of course this makes it a bit messy if you’re not quick and smooth. That’s up to you. |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Sun Jul 20, 2025 8:13 pm Post subject: Re: ABA Vanagon Conversion |
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| MarkWard wrote: |
Does the adapter plate have an access hole for installing the flex plate bolts after mated? You will need this access.
A few tips. When installing the torque converter a gentle turning action helps it seat completely. You should feel each step as it slips in.
Align the engine flex plate with your bolt access hole. Visually set the torque converter so that one of the threaded bosses will line up with the flex plate bolt hole. A tie rap thru the torque converter to the bell housing will hold it in place.
To know you have the torque converter properly seated, bolted to the engine, the torque converter should spin freely before you attach the flex plate bolts. If not, something is not correct.
Last, if your clearance is good, install all 3 bolts hand tight. Then torque them down. I use blue Loctite on the bolts as a precaution. I believe VW recommends replacing them, but I’m not sure. I’ve successfully reused them.
One last thought. It’s a good idea to prefill the torque converter. Of course this makes it a bit messy if you’re not quick and smooth. That’s up to you. |
Thanks for all the advice! I'll definitely follow this. The kennedy adapter does have an access hole on the backside. As soon as I finish touching up my engine bay I'll be using this information. Thank you!
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Mon Jul 21, 2025 7:00 pm Post subject: Re: ABA Vanagon Conversion |
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Removed the torque converter so I can follow the helpful advice I was given. I decided to tackle the surface rust in the engine bay too. After wire wheeling all the rust off, almost half my engine bay was now exposed metal. So I decided to give it a paint job. Now to wait for thr TC seal.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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OlisGarage
Samba Member
Joined: June 01, 2022
Posts: 243
Location: Indianapolis, IN
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| Posted: Mon Jul 21, 2025 8:21 pm Post subject: Re: ABA Vanagon Conversion |
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Swap is looking good!!!
That engine looks amazing. Nice work on it.
Can’t wait to see it sitting in the bay!!
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1981 VW Vangagon TDI (in progress)
1984 VW Rabbit Convertible (daily)
2003 VW Jetta Wagon TDI (recovering from a hit and run) |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Sun Aug 03, 2025 5:37 pm Post subject: Re: ABA Vanagon Conversion |
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Made some progress on the aba conversion today.
Today marks the day my vanagon has officially became an ABA Vanagon!
My ground clearance at the lowest point is 9.5" inches. I noticed the FAS bar carries the engine a bit lower than the wbx was. Is this normal?
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111
Last edited by vw62kid on Mon Aug 04, 2025 5:49 am; edited 1 time in total |
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uberaudi
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Joined: June 24, 2013
Posts: 629
Location: Hi-top Country
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| Posted: Sun Aug 03, 2025 9:09 pm Post subject: Re: ABA Vanagon Conversion |
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Congrats! Thats a big move bolting in the conversion!
The FAS bars hang my tdi in about the same position but I flipped my mounts to the top to gain another inch or so as I had room in the bay to make it work.
What are you using for an intake and alternator setup? If I recall those are the highpoints that will interfere with your decklid. You may want to fit those first, then adjust the engine accordingly.
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Mon Aug 04, 2025 10:04 am Post subject: Re: ABA Vanagon Conversion |
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| uberaudi wrote: |
| What are you using for an intake and alternator setup? If I recall those are the highpoints that will interfere with your decklid. You may want to fit those first, then adjust the engine accordingly. |
I was planning on making a custom intake to clear the deck lid but if the FAS bars are designed for that clearance, I may just use the AEG intake. Also, factory alternator location.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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Vanagon Nut
Samba Member
Joined: February 08, 2008
Posts: 10497
Location: Sunshine Coast B.C.
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| Posted: Mon Aug 04, 2025 12:54 pm Post subject: Re: ABA Vanagon Conversion |
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| uberaudi wrote: |
.....
What are you using for an intake and alternator setup? If I recall those are the highpoints that will interfere with your decklid. ..... |
I don't know where the FAS carrier system locates engine crank center relative to 2wd Vanagon body but....
With my 2.1 WBX still installed, I transferred a mark from crank center to the rear apron in engine compartment. With the 50º ABA test positioned to that WBX mark, the ABA intake was ~ 2.5" above engine opening.
Caveat: I modified my early style diesel Vanagon engine carriers to set engine ~ 2.5" lower.
That said, the ABA NON AC accessory capable bracket I used ( PN 037 903 143C ) located the 50º ABA alternator below the engine cover.
Neil.
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1981 Westy DIY 15º ABA
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Wed Aug 06, 2025 5:07 pm Post subject: Re: ABA Vanagon Conversion |
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Small progress today. Decided to turn some wrenches on my birthday. Got the torque converter and flex plate bolted to each other. After that I mounted my down pipe with stainless steel hardware. It's great seeing this thing finally bolt together.
I also bolted the alternator on, it clears the decklid! So now I'm going to bolt on the intake manifold to test for clearance next.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111
Last edited by vw62kid on Wed Aug 06, 2025 9:42 pm; edited 2 times in total |
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67rustavenger
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Joined: February 24, 2015
Posts: 11211
Location: Oregon
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| Posted: Wed Aug 06, 2025 5:28 pm Post subject: Re: ABA Vanagon Conversion |
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Happy Birthday vw62kid.
I haven't been following this thread but, I'll check in on it from time to time.
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Cheap parts are gonna disappoint you.
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Kdj
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Joined: January 28, 2017
Posts: 281
Location: Naptown
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| Posted: Thu Aug 07, 2025 5:46 am Post subject: Re: ABA Vanagon Conversion |
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Great seeing you closing in on the finnish. Been following since the start as an ABA was on my list of swaps. Looks like you can see light at the end of tunnel.
Oh and happy birthday! |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4285
Location: MD
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| Posted: Thu Aug 07, 2025 7:09 am Post subject: Re: ABA Vanagon Conversion |
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| vw62kid wrote: |
| My ground clearance at the lowest point is 9.5" inches. I noticed the FAS bar carries the engine a bit lower than the wbx was. Is this normal? |
That's actually pretty good. My clearance on my Syncro was 11 5/8" with the WBX and is now 7.5" with the EJ25. Definitely not happy with that reduction in clearance, but since I don't really do any serious off roading it's been low on my actual priorities.
I would be happy with 9.5".
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Thu Aug 07, 2025 7:54 pm Post subject: Re: ABA Vanagon Conversion |
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| 4Gears4Tires wrote: |
That's actually pretty good. My clearance on my Syncro was 11 5/8" with the WBX and is now 7.5" with the EJ25. Definitely not happy with that reduction in clearance, but since I don't really do any serious off roading it's been low on my actual priorities.
I would be happy with 9.5". |
Yeah its not that bad of a clearance. All my other cars are lowered so this feels lifted to me haha
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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vw62kid
Samba Member
Joined: January 20, 2013
Posts: 125
Location: Topeka, KS
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| Posted: Thu Aug 07, 2025 8:03 pm Post subject: Re: ABA Vanagon Conversion |
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I decided to go with the ABA intake over the AEG intake. With that being said I am using the AEG heatshield that has the upper plenum support bracket built into it. Problem is, it is made to support the AEG intake manifold. So, I ended up fabricating a way to support the ABA intake while using the AEG heat shield.
Next I put the intake on.
Great news, it fits! It's a tight squeeze, but it fits. May have to remove some foam off the decklid but hardly much at all. Intake is back off for now while I put everything else together.
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62 Ragtop Project (Anthracite Grey)
https://www.thesamba.com/vw/forum/viewtopic.php?t=597378&highlight=
59 Logo Single Cab Project (L345 Light Grey)
90 Vanagon tin-top ABA convserion...work in progress
https://www.thesamba.com/vw/forum/viewtopic.php?t=...1a11892111 |
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uberaudi
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Joined: June 24, 2013
Posts: 629
Location: Hi-top Country
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| Posted: Fri Aug 08, 2025 10:52 am Post subject: Re: ABA Vanagon Conversion |
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Glad it all fit underneath the decklid for ya. What exhaust is that? Looks great!
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Vanagon Nut
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Joined: February 08, 2008
Posts: 10497
Location: Sunshine Coast B.C.
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| Posted: Fri Aug 08, 2025 1:18 pm Post subject: Re: ABA Vanagon Conversion |
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| vw62kid wrote: |
I ....
Great news, it fits! It's a tight squeeze, but it fits. May have to remove some foam off the decklid but hardly much at all. Intake is back off for now while I put everything else together. |
My ABA with stock intake seems to be at nearly the same height position. For various reasons, with a bit of foam removed from engine cover, I set engine so it *just* clears the engine cover. Even so, required or not, I cut a small hole in engine cover to allow a hair more room for the intake.
Hole in engine cover is covered with duct tape. Though the intake doesn't seem to soak excessive amounts of engine heat fwiw, no visible signs of heat damage at tape or cover after ~ 60K km's.
Neil.
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panel
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vw62kid
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