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pedrokrusher
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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 Posted: Fri Jul 19, 2013 5:50 pm Post subject: |
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Edit: Since it was the beginning of page 5, lets add some photos for fun...
My skull shifter knob
Original vw vanagon 5 speed knob... With white for the picture
No white...
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!
_________________
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
Samba Member
Joined: May 06, 2006
Posts: 2714
Location: Salt Lake City UT
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| Posted: Sun Jul 21, 2013 11:06 am Post subject: |
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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).
_________________
1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181 |
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pedrokrusher
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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| Posted: Mon Sep 02, 2013 6:07 pm Post subject: |
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| 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...
_________________
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
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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| Posted: Mon Sep 02, 2013 6:33 pm Post subject: |
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| 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...
_________________
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
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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| Posted: Mon Sep 02, 2013 8:27 pm Post subject: |
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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.
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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  . 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.
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:
Another 30 second something...
And after a 100km ride, the front side...
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.
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.
Did it work? Yes! After 2000km this is what it looks like:
This is it for now... More later on...
_________________
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
Samba Member
Joined: March 05, 2009
Posts: 12115
Location: Port Manteau
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| Posted: Mon Sep 02, 2013 8:48 pm Post subject: |
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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.
_________________
Casey--
'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
'01 Weekender --> full camper
y u rune klassik? |
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pedrokrusher
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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?Waldo?
Samba Member
Joined: February 22, 2006
Posts: 9752
Location: Where?
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| Posted: Mon Sep 02, 2013 9:18 pm Post subject: |
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| 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.
Last edited by ?Waldo? on Mon Sep 02, 2013 9:25 pm; edited 1 time in total |
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pedrokrusher
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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Steve M.
Samba Member
Joined: July 30, 2013
Posts: 6829
Location: Fort Lauderdale, Fl.
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| Posted: Sat Mar 01, 2014 8:05 am Post subject: |
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| Great thread Pedro! Thanks for the answers to my questions and inspiration! |
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svenakela
Samba Member
Joined: July 19, 2006
Posts: 776
Location: Ekerö
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| Posted: Sat Mar 01, 2014 8:28 am Post subject: |
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| 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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Waldi
Samba Member
Joined: February 28, 2014
Posts: 1752
Location: Germany
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| Posted: Sat Mar 01, 2014 10:11 am Post subject: Best ratio for 1,9 engines |
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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
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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pedrokrusher
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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pedrokrusher
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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Waldi
Samba Member
Joined: February 28, 2014
Posts: 1752
Location: Germany
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| Posted: Sun Mar 02, 2014 9:25 am Post subject: |
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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
Samba Member
Joined: July 11, 2011
Posts: 654
Location: Montreal, Quebec, Canada
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Howesight
Samba Member
Joined: July 02, 2008
Posts: 3274
Location: Vancouver, B.C.
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| Posted: Sun Mar 02, 2014 2:28 pm Post subject: |
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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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'86 Syncro Westy SVX |
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crazyvwvanman
Samba Member
Joined: January 28, 2008
Posts: 9920
Location: Orbiting San Diego
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| Posted: Sun Mar 02, 2014 5:55 pm Post subject: Re: Best ratio for 1,9 engines |
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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
Samba Member
Joined: February 28, 2014
Posts: 1752
Location: Germany
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