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New to me westy, AAZ? MTDI?
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Syncroincity
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PostPosted: Thu Aug 30, 2012 10:21 pm    Post subject: Reply with quote

The crank pulley is an easy mod. Get a 1Z or AHU TDI crank sprocket (with the D) and simply file a flat spot anywhere on the crank to that profile.
It needs to be press-fit, so go down just enough where it wants to fit, but doesn't slide on; the crank bolt will press it on.
I did mine at home (with the crank out of the block) with a dremel to get close then a flat file to finish it. Go slow, and check the fit often; if you go too big you'll have to weld it and re-shape.
Make sure you have the free-wheel clutch (TDI) pulley on the alternator, too, that's where all the stress comes from that eats up the AAZ sprocket notch; that alternator has got some momentum in it, and the way the diesel motor decelerates to idle rapidly causes big forces on the sprocket.
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Rallyedude
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PostPosted: Fri Aug 31, 2012 5:16 am    Post subject: Reply with quote

Pics of last night's work [img]
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Step one of many on the mechanical is done!
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Rallyedude
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PostPosted: Fri Aug 31, 2012 5:49 am    Post subject: Reply with quote

Where's my tranny code? Maybe I'm blind but I can't find it. Thx
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?Waldo?
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PostPosted: Fri Aug 31, 2012 9:23 am    Post subject: Reply with quote

Stock diesel transmissions codes are named for blondes - DZ and DM.

You will want taller gearing for either engine, but the TDI will require custom gears. AAZ is happy with stock WBX or air-cooled trans gearing. I think your $1000 estimate for the added cost of a TDI install is low unless you are comfortable personally re-gearing the trans and building the mTDI pump or doing the wiring and don't give any value to your labor.
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Rallyedude
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PostPosted: Fri Aug 31, 2012 9:43 am    Post subject: Reply with quote

Dizzy and dumb ?
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svenakela
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PostPosted: Fri Aug 31, 2012 12:05 pm    Post subject: Reply with quote

I have an AAP box and a 1Z TDI and it's still too much rev. I agree with Andrew, regearing is preferred.
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86syncrowesty
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PostPosted: Fri Aug 31, 2012 12:22 pm    Post subject: Reply with quote

BrownBertha wrote:
if your mice were like mine be sure to rip out the dash and check the heater box. tricky mice.


Yep, I got a lap full of sunflower seed casings on a nice hot day when I forced open the vent on the driver side. I guess the PO never opened them.
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?Waldo?
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PostPosted: Fri Aug 31, 2012 12:40 pm    Post subject: Reply with quote

Rallyedude wrote:
Anyone need 1.6 na parts ? Cheap cheap ! Evidently not the bars , pan , tranny . But intake ,pulleys , alternator , etc . Lmk


Unless you are adding A/C, you might want to consider keeping the v-belt drive. It is less stress on the crank sprocket.
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Rallyedude
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PostPosted: Fri Aug 31, 2012 3:17 pm    Post subject: Reply with quote

Right now the van has no ac or ps . I'd like to add both eventually . I agree with you that v belts can cause less stress . But serpentine belt set ups are super reliable . I'll be running serpentine belt as an added bonus you get a more modern reliable alternator . Tore the trans off today , more cleaning . Found the code , dm . Also pulled off specific swap parts needed of the motor .
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Rallyedude
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PostPosted: Fri Aug 31, 2012 3:26 pm    Post subject: Reply with quote

Andrew A. Libby wrote:
Stock diesel transmissions codes are named for blondes - DZ and DM.

You will want taller gearing for either engine, but the TDI will require custom gears. AAZ is happy with stock WBX or air-cooled trans gearing. I think your $1000 estimate for the added cost of a TDI install is low unless you are comfortable personally re-gearing the trans and building the mTDI pump or doing the wiring and don't give any value to your labor.


If I were to put on of my AAZ's in it would be done as a full rebuild . I'd have @ 1K in it plus my time . My AHU is good to go except a t-belt. I'd outsource the pump work . So that offsets money saving of the ahu not needing a rebuild . Ahu will save on rebuild time . Either way I think I'd regear. Anyhow , I've got the choice of either motor . Theyre sitting at my shop . So , tdi it is . I will be building my own trans .
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Rallyedude
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PostPosted: Fri Aug 31, 2012 4:24 pm    Post subject: Reply with quote

Reading on gear ratios the dm code has a 5.43 r&p is that correct? It seems to be the numerically highest ratio you can get . I have trans from an 85 doka . I believe it should be a 4. 57 or 4.86 ? The case is shot . Any reason why that r&p wouldn't work for me ? I still have to see about 3&4 gears . But usually bringing down the r&p when you up power works well and helps cruising speeds .

What would be ideal r&p ratio and 3&4 to match ? That is running an ahu .
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jackbombay
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PostPosted: Fri Aug 31, 2012 4:35 pm    Post subject: Reply with quote

Rallyedude wrote:


What would be ideal r&p ratio and 3&4 to match ? That is running an ahu .


My AHU westy had a 4.57 R&P and a .77 4th, 3rd was 1.17 IIRC, and I had 27.5" tall tires (10% more distance per rotation than stock tire size) and I though that combination was just about perfect, 2750 RPM at 67 MPH. (vag-com for RPM And GPS for speed)
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Rallyedude
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PostPosted: Fri Aug 31, 2012 4:43 pm    Post subject: Reply with quote

Cool thanks for the info .

Ring and Pinions switchable between different cases? That is diesel to gas cases . Different number of case ribs .

Who do you buy gears from ? Thought AA was the go to guy but apparently he wants to build transmissions not just sell parts . That's cool , and I get it . Just looking for another solution . Don't really want to ship my tranny to the other side and back when I'm comfortable taking care of it in house .
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