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5 speed AAP transmision mated to a TDI ALH advise needed
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pedrokrusher
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PostPosted: Fri Jul 19, 2013 5:50 pm    Post subject: Reply with quote

Edit: Since it was the beginning of page 5, lets add some photos for fun...

My skull shifter knob
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Original vw vanagon 5 speed knob... With white for the picture
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No white...
Image may have been reduced in size. Click image to view fullscreen.


Yes it was weird just the first day to shift from first to second. The next day it actually felt good! I have to add that modifications was made to make shifting easier.

First, there is a little ball with a spring that keeps the shifter going freely from the middle towards the left. Well that spring was shortened by almost half to release some tension to make it go to the left easier... I know it does not make much sense the way I write... The original tension was way too hard and made it feel very annoying to the point of hating it, not anymore...

Second, a spring was added to keep the shifter from going freely towards the right. This spring helps keeping the shifter in the middle when you put it to neutral. All the time. That's because the original shifter is set to move totally free between 2-3 and 4-5... Weird hey! Now it goes and stays at neutral at 2-3.

So when starting from a dead stop, all I do is push the shifter towards the left then down for first gear. When shifting for second, all I do is pull the shifter out of first gear with the palm of my hand, and it goes automatically to the middle, right away, I just pull it forward with the palm of my hand and it goes right away into second gear... That's it. You don't need to "look" for that second gear. Easy!


In regards to the previous posts...
Thanks Hans j and rsxsr for the lead on the gas pedal signal. I have something to look into now that I have the focus to work on this swap code fault.

ALH power!
Cool Cool Cool Cool
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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hans j
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PostPosted: Sun Jul 21, 2013 11:06 am    Post subject: Reply with quote

It looks like pin 27 on the 121 pin ECU connector is the tach output. .35mm green/brown wire. Pretty sure I just hooked mine up to the stock tach wire that went to the coil. That should take it all the way up to the cluster. Then I modified my gauge like the link and no issues (except I believe I have a cold solder joint and have to smack the cluster occasionally to get it to wake up).
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pedrokrusher
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PostPosted: Mon Sep 02, 2013 6:07 pm    Post subject: Reply with quote

rsxsr wrote:
Have you watched the accel pedal with the VCDS software when this happens? The early ALH had a dashpot potentiometer for the accel pedal. I used a later all in one pedal and found that two wires needed to be reversed. I stared at the wiring diagrams for a long time of the two versions before I saw the subtle difference. I did not have your symptom, but I believe you can watch the accel pedal in the VCDS software. As long as you can duplicate the symptom, you should be able to figure it out. markw


hans j wrote:
It looks like pin 27 on the 121 pin ECU connector is the tach output. .35mm green/brown wire. Pretty sure I just hooked mine up to the stock tach wire that went to the coil. That should take it all the way up to the cluster. Then I modified my gauge like the link and no issues (except I believe I have a cold solder joint and have to smack the cluster occasionally to get it to wake up).


Hi Mark and Hans, sorry I did not take the time to check this issue as it's something that does not stop me from doing trips. I'll look into it a little later in late sept or oct.

For the ones just reading this, it's a symptom that I've been living with since the beginning... It's when I start the engine, the first gas pedal that I do, the van starts rolling and when the RPM reaches a certain speed, like 1500 RPM, the engine goes automatically back to idle mode. The solution is pretty simple, you release the gas pedal and press again on the gas pedal and all is normal for the rest of the time, until you stop the engine and start it again. It's my only ''swap code fault''.

...More info in the next messages in a couple minutes... I take some time to type in english...
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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pedrokrusher
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PostPosted: Mon Sep 02, 2013 6:33 pm    Post subject: Reply with quote

pedrokrusher wrote:
Howesight wrote:
Pedro said:

"KM/H (MPH) accuracy: GPS
The speed was verified by GPS, since there is a difference between the two. My speedometer shows (edit) 100 km/h when the GPS is at (edit) 104 km/h, because of the 16 inch wheels. So the speedo covers 4% (edit) less kilometers than reality. When calculating the consumption, I (edit) add 4% in the kilometers to get a more accurate calculation for the MPG."

Hey Pedro:

I have one of Daryl's syncro gearboxes with the stock 4:86 axle ratio and 1.16 and 0.70 third and fourth gears. I used 215/75/16 BFG AT tires (almost 29 inches).

Using GPS, I found that at an indicated 60 mph per the speedo, I was actually doing 66mph by the GPS.

Interestingly, my odometer, compared to the GPS ( and the odometer test areas in Washington), was 100% accurate, despite the gearing and wheel size. Go figure.

You might consider measuring a given distance and seeing if your odometer is accurate. I am very impressed with your mileage figures, I get about 19 or 20 US mpg in my Syncro SVX - - IF I go no faster than 60 mph.

However, if I go 70 or 75, it drops to 14 US mpg, especially in the mountains. I am so jealous!


Yes! You are absolutely right that I need to look into verifying the odometer separately from the speedometer... I thought about it a while ago and completely forgot about it! Then Jon Slider PM me and mentioned the same thing... That will be my next assignment, and maybe there will be some more edits to my MPG post from yesterday... oh well..

Interestingly you have 6% difference between your speedo and GPS. I guess your bigger tires made that little extra 2% more than my tires. I have 4% difference.

Yes its fantastic to make that kind of MPG... but everything comes with a price. My goal was very specific, and I finally reached that goal, and now I can drive my TDI dream machine with a big smile for a long long long time.



Well I took some time to verify this while going to Sand Banks provincial park in Ontario. Nice place not too far from home, a 4 hour drive.

As soon as i reached Ontario I noted the kilometer post: 828km.
And the vanagon odometer was: 318922 km

When I reached the exit from the highway it was: 566km.
And the vanagon odometer was: 319174

So the total highway kilometers on the ground was:
828 - 566 = 262km

And the vanagon odometer calculated:
319174 - 318922 = 252km

Simply put, if I take 252km plus 4% it gives 262km !!!!

So the speedometer and the odometer on my van are equal.

Thank god! That means all my calculations are accurate...

And the consumption on this trip was 8,014 litres per 100 km (29.4MPG).
I tried to go at 120km/h (75MPH) but there was too much traffic and construction zones, so average was between 105-110km/h (65-70MPG).

More to come...
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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pedrokrusher
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PostPosted: Mon Sep 02, 2013 8:27 pm    Post subject: Reply with quote

So back in january 2012, on page one, i discussed about my welded oil pan... For informational purposes for future samba members thinking doing a TDI swap involving welding an oilpan, I've put together the advise from other sambatistas in this post... plus some more below...


Zeitgeist 13 wrote:
pedrokrusher wrote:
Hi Jabba, so here is my custom oil pan. As stated before, it is the base of the ALH TDI oil pan welded with the bottom part of the vanagon diesel oil pan. I could not figure out why there was always some oil stains on the welded pan. I figure it out later that, with time, the oil will go tru the aluminum welds and create this leak. It is very slow, but annoying. I might consider to paint the interior of the pan, as suggested somewhere here on thesamba. i don't know what kind of paint to use.

Image may have been reduced in size. Click image to view fullscreen.



Try using some Glyptal

Thanks again Zeitgeist 13, I will work on that Glyptal this coming winter.



bosruten wrote:
Hi pedrokrusher, For next time, welders need to spend extra time prepping alum., remove the natural occurring oxides on the surface with a stainless brush, use a alcohol based cleaner after. Your pan most likely leaked from the get-go...just took awhile to get to the outside.
For lack of proper NDE equip/methods...Diesel gas/petrol works well to reveal flaws. Fill up the pan, have a beer and hope you did it right the first time, or you go through the prep. again Rolling Eyes. And a nice little AC square wave inverter with a pedal helps.

Your ride looks sweet!



jabba wrote:
Bosruten is right you need a very good preparation on the 2 pans before weld them together. Aluminium is like a sponge and when you warm it too much, the holes become bigger. If there is oil when you weld, you can create a boiling. Also, you can't Begin the weld wherever because the metal reacts by twisting itself.
I've done the preparation on my oil pan but let do a professional welder for the weld. He used argon and weld inside and outside the pan and there is no leak.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Pedro, i have seen the original bracket for the exhaust on your pan. I trust my welder but to support my exhaust i didn't use this bracket.

Thanks guys for the advise!





so now, driving the TDI westy this summer 2013, I noticed a little more oil droplets accumulation on the tailgate than last year, which was very minimal, and more oil accumulation on the bottom side of the oil pan. Last week I was looking for any kind of leaks under the van before a 2000km trip. The van had run on the highway before so it was pretty hot, it was on ramps and me underneath it while the engine was running, and noticed this...

I cleaned down the oil pan with a rag and 10 seconds later I noticed two pin holes where oil was dripping out:
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Another 30 second something...
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And after a 100km ride, the front side...
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And after a 100km ride, the rear side of the oilpan is not an issue really... For now. Glyptal to the rescue this coming winter.
Image may have been reduced in size. Click image to view fullscreen.



So I called a local welder locally and the advise was to try to hammer down with a punch the exact two spots and see if by doing so, I could squeeze enough material to stop the leak for now until this winter when I'll work on that issue with Glyptal.
Image may have been reduced in size. Click image to view fullscreen.

Image may have been reduced in size. Click image to view fullscreen.


Did it work? Yes! After 2000km this is what it looks like:
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Image may have been reduced in size. Click image to view fullscreen.


This is it for now... More later on...
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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Zeitgeist 13
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PostPosted: Mon Sep 02, 2013 8:48 pm    Post subject: Reply with quote

Yeah, Glyptal spreads on pretty thick, especially when done in multiple coats. Just clean the surfaces exceptionally well, and I think this will eliminate all leaks. I baked the pan at 250F for at least a half hour after the second coating.
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pedrokrusher
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PostPosted: Mon Sep 02, 2013 9:15 pm    Post subject: Reply with quote

Zeitgeist 13 wrote:
Yeah, Glyptal spreads on pretty thick, especially when done in multiple coats. Just clean the surfaces exceptionally well, and I think this will eliminate all leaks. I baked the pan at 250F for at least a half hour after the second coating.


Thanks Zeitgeist 13, I'll look into that... I did not know about the baking part... I just imagine my wife's face when I do that in our kitchen... hehehe...

When you say just clean the surfaces exceptionally well, what do you suggest?
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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?Waldo?
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PostPosted: Mon Sep 02, 2013 9:18 pm    Post subject: Reply with quote

pedrokrusher wrote:
When you say just clean the surfaces exceptionally well, what do you suggest?


Just run it through the dishwasher a couple times...to make the wife really happy.
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Last edited by ?Waldo? on Mon Sep 02, 2013 9:25 pm; edited 1 time in total
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pedrokrusher
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PostPosted: Mon Sep 02, 2013 9:21 pm    Post subject: Reply with quote

[quote="Andrew A. Libby"]
pedrokrusher wrote:
Zeitgeist 13 wrote:
When you say just clean the surfaces exceptionally well, what do you suggest?


Just run it through the dishwasher a couple times...to make the wife really happy.


Hahahaha!!!
Laughing Laughing Laughing

Good one Andrew!
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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Steve M.
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PostPosted: Sat Mar 01, 2014 8:05 am    Post subject: Reply with quote

Great thread Pedro! Thanks for the answers to my questions and inspiration!
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svenakela
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PostPosted: Sat Mar 01, 2014 8:28 am    Post subject: Reply with quote

Clean it and ask a TIG welder to sweep over the seam with the TIG. Much safer than paint and stuff and you can reassemble after 25 minutes.
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PostPosted: Sat Mar 01, 2014 10:11 am    Post subject: Best ratio for 1,9 engines Reply with quote

I have tryed alot of ratios.
The best was/is a 4,14 ring-pinion and 0,78 4/5th gear.
On a 2wd ofc. U can use also 225/70-15 tires on the rear and something simular like original in front.

Here u can try all posibilitis.
www.t3-infos.de/images/Getriebeauslegung.xls
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pedrokrusher
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PostPosted: Sun Mar 02, 2014 7:00 am    Post subject: Reply with quote

Steve M. wrote:
Great thread Pedro! Thanks for the answers to my questions and inspiration!


Thanks you very much, Steve! It means a lot to me. It was a lot of work to achieve this goal.

I have learned a lot here on thesamba from other peoples projects, problems, ideas. So this is my way of helping back the vanagon community.

I'm very happy that it inspires you... But wait, i still have some more data to enter here... My westy is hibernating in my cold garage, with the last gas receipts. I should go get them and let you know the outcome... (hint... 1000 kms with one gas tank... 85 l gas tank that is...)
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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pedrokrusher
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PostPosted: Sun Mar 02, 2014 7:07 am    Post subject: Reply with quote

svenakela wrote:
Clean it and ask a TIG welder to sweep over the seam with the TIG. Much safer than paint and stuff and you can reassemble after 25 minutes.


Thanks Svenakela for your input. Since i did nothing yet on the oil pan, I can still do that. I also believe it will be the best solution to weld, and then its done for life!

I guess i got a little lazy by doing nothing about it since there is no more drops of oil on the rear hatch, but i should find some time soon to completely finalise this detail. A cold garage is not my thing... Next, the exhaust system.
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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pedrokrusher
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PostPosted: Sun Mar 02, 2014 7:24 am    Post subject: Re: Best ratio for 1,9 engines Reply with quote

Waldi wrote:
I have tryed alot of ratios.
The best was/is a 4,14 ring-pinion and 0,78 4/5th gear.
On a 2wd ofc. U can use also 225/70-15 tires on the rear and something simular like original in front.

Here u can try all posibilitis.
www.t3-infos.de/images/Getriebeauslegung.xls


Thanks Waldi for your input!

Yes! The 4.14 R&P with a 4th gear (4 speed trans) or 5th gear (5 speed trans) 0.77 gear is what I have too! We are now 3 people that has those gearings: rsxsr, waldi, and pedrokrusher.

I know some web sites calls that gear a 0.77 and others a 0.78. Daryl (RIP) at AA Transaxle called it a 0.77 by the way. I guess its only in the way they round up their math, but still the same gear ( I hope! ).
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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Waldi
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PostPosted: Sun Mar 02, 2014 9:25 am    Post subject: Reply with quote

I personaly dont use the 4,14, but i did some gearboxes for AAZ and mech 1Z,AHU.
I use a 4,85x0,82 in my AAZ Syncro with 205/80-16 wheels, or 215/75-15 when im pulling a heavy trailer.
The 0,78 gear is the original from Syncro 14 diesel gearboxes. It is no more avalable new in germany .
Only a 0,74, or the original 2-wd 0,82.
I know Weddle has some 0,77 on his side.
I would like to know if somebody know about problems with the big teeth on this Weddle gears ?
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pedrokrusher
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PostPosted: Sun Mar 02, 2014 9:35 am    Post subject: Reply with quote

Waldi wrote:
I know Weddle has some 0,77 on his side.
I would like to know if somebody know about problems with the big teeth on this Weddle gears ?


I was told by other members that its noisier at highway speeds. Personally i cannot hear mine because of my too simplistic loud exhaust system...
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Pedro
1989 vanagon Karmann Gipsy #652, TDI AFN
1991 vanagon westfalia conversion TDI ALH Silverfox
ex-1989 vanagon syncro passenger Syncrofox (Sold)
http://www.thesamba.com/vw/forum/viewtopic.php?t=598791&highlight=
http://www.thesamba.com/vw/forum/viewtopic.php?t=493964&highlight=speed+aap+trans
http://www.thesamba.com/vw/forum/viewtopic.php?t=496589&highlight=carrier+bars
http://www.thesamba.com/vw/forum/viewtopic.php?t=506025
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PostPosted: Sun Mar 02, 2014 2:28 pm    Post subject: Reply with quote

In my SVX powered Westy Syncro, I have never been able to hear either the 3rd or 4th Weddle gears whine, even coasting with the engine off, clutch disengaged. I do run Swepco 210 gear oil, which may or may not quiet my gearbox somewhat.
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PostPosted: Sun Mar 02, 2014 5:55 pm    Post subject: Re: Best ratio for 1,9 engines Reply with quote

There are 2 different gear sets, so 2 ratios.
The older set was 49/64 teeth, = .766 [.77]
The later set is 39/50 teeth, = .780 [.78]

The .78 has fewer and thus bigger teeth on both gears of the set.

Each "gear" in the 4 speed or 5 speed is really 2 gears that mesh, one on each of the 2 shafts that run through the gearbox. The ratio of the tooth count on the 2 gears is what gives the gear number.

Mark



pedrokrusher wrote:


I know some web sites calls that gear a 0.77 and others a 0.78. Daryl (RIP) at AA Transaxle called it a 0.77 by the way. I guess its only in the way they round up their math, but still the same gear ( I hope! ).
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Waldi
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PostPosted: Mon Mar 03, 2014 1:29 am    Post subject: Reply with quote

Here we call the 49x64 gear 0,76.
It was in older 5-g 2wd gearboxes.
U can find a t3-getriebe.pdf on
http://www.t3-infos.de/t3-infos_j.html
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