Betsys 2wd to Syncro Conversion

It’s happenening! I’m going all out on quality hardware; Burley gear, GT hardware, etc. This may take a year to complete!

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

11/09/2018

I have a sale pending for a fuel line fire syncro donor for - $3500

Research

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

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

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 not use the front hubs when installing in a Syncro.

Mao

Coolant System

So there are changes here

Coolant Pipes

I’ll need to sell my Stainless Steel TDI Coolant Pipes for Syncro SS Coolant Pipes @ Van-Cafe