Betsys 2wd to Syncro Conversion
It’s happenening! This may take a year or two to complete, as I'm refreshing ALL Syncro gear.
- 1 Community Builds
- 2 Purchases
- 3 Decisions
- 4 Research
- 5 The Little Things
- 6 Comments
Some are already ahead of me of converting their 82' diesel. One such is
Decided I’ll need the diesel syncro fuel tank to keep it 50degrees - $243
Bought GT's intro Gear Housing Carrier for the 094 Syncro transmission - $699
GoWesty syncro fuel tank refresh; sender, vent nipples, straps - $452
I bought a 1.8t turbo fire 86 syncro with rear locker donor for - $3500 + $1288 (to ship)
I bought an used Syncro speedometer for - $150
Description: needle spins nicely. but the od numbers and trip only move slightly, dusty or stuck.
I bought a cracked Syncro Locker Console for - $82; eventually get a 3d print non-cracked, but it's functional
I bought a new remake syncro gear cross member that can be swapped out with the 82' cross member. The reason I went this route also was to have the existing syncro in tact so I could determine proper balance / measurements of install.
TH Parts & More - Gear Support $600 shipped
- Sport VC
- Front Locker - Peloquin Automatic Torque Biasing (ATB) locking differential
- Rear Locker (included with donor)
- Guard Transaxle - (GT) Billet Aluminum Gear Carrier Housing)
- Guard Transaxle (GT) mainshaft 1&2
. . .
Syncro Specific Components
You need the Syncro's specific speedometer, as it has different rotations due to the front diff than the 2wd.
Diesel Syncro Specific Components
Petrol (Gasoline) Syncros were very common in North America. However, no diesels were in North America from VW directly. There were plenty of Diesel Syncros in Europe and other areas.
In order to keep a 50degree diesel install for a Syncro you need a "Diesel Syncro Fuel Tank" not the petrol version. They make the same p/n for a van & doka tank, but the filler location Differs. Make sure it comes out of a van. The sinka / doka tank filler can be plugged and the 'van' hole cut if no other van tanks can be found.
The Stainless Steel straps offered fit both.
Here are some photos. Note the curve in the center for where the diesel starter would clear. It's quite different looking than a petrol fuel tank.
Diesel Syncro Carrier Bars
The Diesel Syncro uses carrier bars similar to the '83 but the through-bolt for the engine mount is located about 1.5" lower.
- 83' Diesel Syncro Vanagon Carrier Bars Tony
Syncro Components for AWD
Here is the list (besides tranny, pumpkin, and front diff) that I know of till I start cutting etc.
- Front Sub Frame
- Front Suspension
- Steering Rack Mount
- Transmission Mount
Two things regarding this. As I'm doing a diesel install at 50degrees I need the following:
- 83' Diesel Syncro Vanagon Carrier Bars Tony
This is always the tricky part.
The consensus is a 4.86 Ring & Pinion is the way to go for a syncro TDI transplant.
As for the gearing;
1.88 for 2nd is popular if you use a Euro mainshaft
1.14 is popular for the 3rd gear.
As always 4th is all over the map, likely due to tire sizes. The most popular from known drivers are;
- 0.77 with 30" tires
- 0.73 with no larger than 28" tires
Now, let's look at the RPM for my sort of driving 63-70mph
Most common tire sizes; 27-30 that I may do:
- @ 1.14 @ 2850rpm @ 39.8mph
- @ 0.70 @ 2850rpm @ 64.8mph
- @ 0.73 @ 2850rpm @ 62.2mph
- @ 0.77 @ 2850rpm @ 58.9mph
- @ 1.14 @ 2950rpm @ 41.2mph
- @ 0.70@ 2950rpm @ 67.1mph
- @ 0.73@ 2950rpm @ 64.3mph
- @ 0.77@ 2950rpm @ 61.0mph
- @ 1.14 @ 3000rpm @ 41.9mph
- @ 0.70@ 3000rpm @ 68.2mph
- @ 0.73@ 3000rpm @ 65.4mph
- @ 0.77@ 3000rpm @ 62.0mph
- @ 1.14 @ 2850rpm @ 41.3mph
- @ 0.70 @ 2850rpm @ 67.3mph
- @ 0.73 @ 2850rpm @ 64.5mph
- @ 0.77 @ 2850rpm @ 61.2mph
- @ 1.14 @ 2950rpm @ 42.7mph
- @ 0.70@ 2950rpm @ 69.6mph
- @ 0.73@ 2950rpm @ 66.8mph
- @ 0.77@ 2950rpm @ 63.4mph
- @ 1.14 @ 3000rpm @ 43.5mph
- @ 0.70@ 3000rpm @ 70.9mph
- @ 0.73@ 3000rpm @ 68.0mph
- @ 0.77@ 3000rpm @ 64.4mph
- @ 1.14 @ 2850rpm @ 42.8mph
- @ 0.70 @ 2850rpm @ 69.8mph
- @ 0.73 @ 2850rpm @ 66.9mph
- @ 0.77 @ 2850rpm @ 63.4mph
- @ 1.14 @ 2950rpm @ 44.3mph
- @ 0.70@ 2950rpm @ 72.2mph
- @ 0.73@ 2950rpm @ 69.2mph
- @ 0.77@ 2950rpm @ 65.6mph
- @ 1.14 @ 3000rpm @ 45.1mph
- @ 0.70@ 3000rpm @ 73.4mph
- @ 0.73@ 3000rpm @ 70.5mph
- @ 0.77@ 3000rpm @ 66.8mph
So, let's look at the tire ratios I'd likely use
General Grabber AT2:
- 215/65/R16 with a load index of 98 @ 1654lbs a tire @ 27.0" - currently have
- 215/70/R16 with a load index of 100 @ 1764lbs a tire @ 27.9"
- 225/75/R16 with a load index of 108 @ 2205lbs a tire @ 29.3"
I currently have the Front & Rear Small Car Big Brake kits installed for my 2WD.
They will work! Per SmallCar:
With the kit you have you do not need to buy anything to convert to a Syncro. Just do not use the front hubs when installing in a Syncro.
So people say these need to change, BUT looking at the donor pipes and my Stainless Steel diesel pipes, I think I'll be good.
The Little Things
DiffLock Console PCB Board
You can get one from SmallCar