Betsys 2wd to Syncro Conversion
IN PROGRESS!!!
It’s happenening! I’m going all out on quality hardware; Burley gear, GT hardware, etc. This may take a year to complete!
Contents
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 bought a fuel line fire 86’ syncro w/rear locker donor for - $3500
Decisions
Transaxle
Options:
- Front Locker - Peloquin Automatic Torque Biasing (ATB) locking differential
- Rear Locker
- (Guard Transaxle - GT) Billet Aluminum Gear Carrier Housin)
. . .
Research
References
Samba - Converting a 2WD Westy into a Syncro Westy
Diesel Syncro Specific Components
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. 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.
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:
- 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
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
So there are changes here
Coolant Pipes
It’s in air if my Stainless Steel TDI Coolant Pipes will work
