Betsys 2wd to Syncro Conversion

IN PROGRESS!!!

It’s happenening! This may take a year or two to complete, as I'm refreshing ALL Syncro gear.

Purchases

08/01/2018

Decided I’ll need the diesel syncro fuel tank to keep it 50degrees - $243

09/01/2018

Bought GT's intro Gear Housing Carrier for the 094 Syncro transmission - $699

10/30/2018

GoWesty syncro fuel tank refresh; sender, vent nipples, straps - $452

11/09/2018

I bought a 1.8t turbo fire 86 syncro with rear locker donor for - $3500 + $1288 (to ship)

01/18/2019

I bought an used Syncro speedometer for - $150 shipped

Description: needle spins nicely. but the od numbers and trip only move slightly, dusty or stuck.

Decisions

Front Diff

Options:

• Sport VC
• Front Locker - Peloquin Automatic Torque Biasing (ATB) locking 
differential

Transaxle

Options:

• Rear Locker (included with donor)
• Guard Transaxle - (GT) Billet Aluminum Gear Carrier Housing)
• Guard Transaxle (GT) mainshaft 1&2

. . .

Research

References

Samba - Converting a 2WD Westy into a Syncro Westy

Samba - 2WD to 4WD Conversion

Diesel Syncro Specific Components

Speedometer

You need the Syncro's specific speedometer, as it has different rotations due to the front diff than the 2wd.

Fuel Tank

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 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 quiet different looking than a petrol fuel tank.

Diesel Syncro Carrier Bars

The Diesel Syncro uses carrier bars similar to the 82'

• 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

Transmission

Fitment

Two things regarding this. As I'm doing a diesel install at 50degrees I need the following:

• 82' Diesel Vanagon Bellhousing - Weddle (New or USED

• 83' Diesel Syncro Vanagon Carrier Bars Tony

Gearing

T3gearbox ratios here

This is always the tricky part.

The consensus is a 4.86 Ring & Pinion is the way to go for a 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:

Ratios

Tire Height Chart

RPM Calculator

Scirocco (Click Gears on bottom)

26"

@ 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

27"

@ 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

28"

@ 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"

Brakes

I currently have the Front & Rear Small Car Big Brake kits installed for my 2WD.

They will work! Per SmallCar:

Hi William,

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.

Mao

Coolant System

Coolant Pipes

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.