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  #1  
Old May 19th, 2014, 11:44 AM
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What's the record ?

What's the fastest anyone here has done a complete soup to nuts conversion ? Ie engine/trans/transfer case swap on a 90 or 110 ?
Raub is going to trailer his Tithonus up and we are going to remove that 2.5 natural crap (you listening Newman ?) and install the Tdi setup from Dave Lucas's truck this coming weekend. Everything will be replaced except axles and we will re-use his drive shafts. Steering will be swapped from manual to power. We may chronicle our antics here if we don't drink too much and forget to take pictures. Not that that could ever happen....

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  #2  
Old May 19th, 2014, 11:45 AM
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4.5 years
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  #3  
Old May 19th, 2014, 11:49 AM
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Quote:
Originally Posted by grnrvrs View Post
4.5 years
He's allowing me 3 days
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  #4  
Old May 19th, 2014, 11:59 AM
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Really hoping someone with a GoPro lends it to you for a time lapse video.
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  #5  
Old May 19th, 2014, 12:11 PM
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Just realized he wants Monday to drive back to S. Florida so its really going to be "game on" time.
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  #6  
Old May 19th, 2014, 12:57 PM
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Probably pretty quick if both the donor and recipient trucks are in the same place...based on my limited experience, the actual swap could easily be done in a weekend...it's the waiting for parts you don't have part that takes the most time!
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  #7  
Old May 19th, 2014, 03:44 PM
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This will be a drive it in, drive it back out scenario. Not a crane one out, crane one in, and take 6 mos to do the rest. Usually these projects go sideways because of fasteners etc. Really hoping the Tithonus program the truck went through makes the difference. 1 truck and a pallet which arrived today. Raub is hunting for a lhd power steering box.
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  #8  
Old May 19th, 2014, 03:51 PM
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It should go quick I included a bunch of extras as well.

Make sure the timing belt gets changed not sure when it was done last.
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  #9  
Old May 19th, 2014, 04:03 PM
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Quote:
Originally Posted by dave_lucas View Post
It should go quick I included a bunch of extras as well.

Make sure the timing belt gets changed not sure when it was done last.
Good to know. Raub add that to your list.
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  #10  
Old May 19th, 2014, 04:18 PM
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Man I would love to come up and help. When I did mine I didn't have any fasteners give me any problems. Everything came apart well.
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  #11  
Old May 19th, 2014, 04:37 PM
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Now that mine is done, I'm pretty sure that you could do the drivetrain in a weekend, provided that you had all of the parts ready to go. What's your plan for the gearbox? My drivetrain is in the stock 300Tdi position and we had to modify my seat box and floorboards to fit. The little things that can slow you down are mostly things that you have to/want to adapt from the ex-MODs running gear, like shift linkage, fuel lines, etc. I was very lucky that Brian had a very well-equipped shop with lots of spare parts and cores that we could scavenge from. There was more scavenging than I anticipated. Even the new and take-off stuff can be a problem. My first steering box was hosed. Some little clutch parts, like the staple and the plastic retaining clip had to be ordered. If you guys want to chat on the phone before you start, PM me and I can brain dump what I remember.

My entire chassis and drivetrain swap took about eight two-day weekends. For two of those weekends, we had an awesome D90 Source turn-out for the dismantle-fest. The rest of the weekends was just me and Brian turning wrenches. The motor was maybe 2 days of that in total.

The Tithonus refurb definitely helps in the dismantling phase. We had to break only a handful of fasteners on the entire project.
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  #12  
Old May 19th, 2014, 04:55 PM
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There should be a new genuine timing belt and tensioner in the box.

Open up the box and see what all is in it might save you from having to buy a bunch of stuff.

even a new set of glow plugs
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  #13  
Old May 19th, 2014, 05:12 PM
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Quote:
Originally Posted by sonoronos View Post
the actual swap could easily be done in a weekend...it's the waiting for parts you don't have part that takes the most time!


This.


Mine took me a couple of months but that included a lot of waiting time for parts to show up.


If you have all the parts, then a weekend is very realistic.


Might be fun to compare a "before and after" 0-60 mph time.
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  #14  
Old May 19th, 2014, 06:01 PM
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Quote:
Originally Posted by meatblanket View Post


Might be fun to compare a "before and after" 0-60 mph time.
2.5 NA = 10 min

TDI = 6 min
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  #15  
Old May 19th, 2014, 06:19 PM
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Quote:
Originally Posted by dave_lucas View Post
There should be a new genuine timing belt and tensioner in the box.

Open up the box and see what all is in it might save you from having to buy a bunch of stuff.

even a new set of glow plugs
Yep, went and looked after reading your "extra's" post. You were running no power steering ? I see two pumps but it looks like you were running without ? The fan shroud took a hit and is busted up but everything else looks great.
The only thing I'm seeing I need are tdi radiator holdown brackets. The 2.5's use the early style.
When Raub called me and asked what I thought about buying your engine I said "Dave is anal, that's a screaming deal". After unwrapping the pallet I started smiling.
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  #16  
Old May 19th, 2014, 06:46 PM
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Got the radiator and oil cooler lines squared away? You probably know already that the earlier versions use imperial flare type fittings and the later ones use O-rings. If you're lucky, all that stuff matches up.
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  #17  
Old May 19th, 2014, 06:51 PM
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Quote:
Originally Posted by Jymmiejamz View Post
2.5 NA = 10 min

TDI = 6 min

That's a little optimistic, don't ya think?


.
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  #18  
Old May 19th, 2014, 07:04 PM
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Ok I'm here! So Doug do you have all this stuff handled?
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  #19  
Old May 19th, 2014, 07:06 PM
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Quote:
Originally Posted by Daddymow View Post
Ok I'm here! So Doug do you have all this stuff handled?
Call Zak and get some tdi rad hold down brackets, and a lhd defender 200tdi high pressure steering hose here by Friday. The disco hose is different so make sure you get the defender one.

Does your dash top pad have an ash tray opening ? Dave included VDO pyrometer, boost, and water temp gauges. Get us a mini mud pod if you have that dash top opening.

------ Follow up post added May 19th, 2014 07:16 PM ------

Quote:
Originally Posted by sonoronos View Post
Probably pretty quick if both the donor and recipient trucks are in the same place...based on my limited experience, the actual swap could easily be done in a weekend...it's the waiting for parts you don't have part that takes the most time!
Ed perhaps the question wasn't clear. I have done many of these. I didn't ask what you arm chair guys think you "could" hypothetically accomplish. I asked what your record is ?



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  #20  
Old May 19th, 2014, 07:18 PM
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Zak, you copy that? Friday STAT! Yes on the ash tray opening.
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