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Author: Subject:  Started work on the Syncro (T4 Rear Discs)
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posted on December 29th, 2013 at 01:12 PM



Thanks Brent for the list of bits required.

I thought you could only easily use a 2003 and earlier model scooby donk as they went can-bus from then on?

Anyway, interesting regarding your tank - mine is a 10/88 model syncro and it has no tank insulation either - must have started that in 89?

I have had a 2.7 6 cyl scooby in mine for the last 17 years and the lack of tank insulation hasnt really been an issue but I plan to do this as well - any link to the insulation seller you found?

Thanks,

Scott




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posted on December 29th, 2013 at 01:25 PM



Also,

Will you need a speed sensor kit?

I think Smallcar have the one that bolts to the gearbox CV - I have always wondered how that would go with it being plastered with mud?




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posted on December 29th, 2013 at 04:42 PM



Got the insulation from http://stores.ebay.com.au/oz-style97/Heat-Shield-/_i.html?_fsub=4580534011&am...

The car never had any issue with fuel tank heat but I thought it would be a good idea to upgrade while I had the tank out, Volkswagen must have insulated the later tanks for a reason.

VSS

I do have a CV style vss left over from my caravelle conversion as I used the Jetta cruise control Hall effect sensor instead. The Jetta sensors are nearly impossible to find now, it took me 6 months waiting on eBay to get the one I used on the Caravelle.

https://lh6.googleusercontent.com/-_bgvVYeDTec/Ur_DeGW6CgI/AAAAAAAAAJY/whuk9-KC1g8/s800/P1040725_%2528Small%2529.JPG




Fastforwardautomotive (Canada) are selling a german made copy on eBay.

http://www.ebay.com.au/sch/fastforwardautomotive/m.html?_nkw=&_armrs=1&am...

https://lh6.googleusercontent.com/-L1kCPqK-xbM/Ur_DdpikcRI/AAAAAAAAAJI/r1b3hNv0riA/s800/%2524T2eC16JHJGkE9no8gJVdBRBB38iWyQ%257E%257E60_12.JPG




and Gowesty have now caught on and have started making a version too.

http://www.gowesty.com/ec_view_details.php?id=23945&category_id=341&c...


https://lh4.googleusercontent.com/-wY6MVynQ1eI/Ur_Dee-TwMI/AAAAAAAAAJU/7cd9rK8OByk/s800/large_415a4daaa783b61d0cf0827098a6cc28.jpg




I like the idea of having the vss at the speedo as it keeps it out of the mud, grease and stray rocks.

Oh and to answer the question, yes I will be needing a vss. Might try a Gowesty one.




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posted on December 29th, 2013 at 07:21 PM



In regard to CAN bus, it was introduced in the US/Canadian market in 2005 but from what I have read Australia didn't get it until 2007.

One way to tell is to look at the OBD-2 port, if pins 6 and 14 are occupied the vehicle has CAN bus and if they are blank the vehicle doesn't have CAN bus.

http://mbed.org/media/uploads/fossum_13/obdii_port1070929671.jpg




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posted on December 31st, 2013 at 12:32 PM



Brent,

Thanks for all that info - will be ideal for when I get around to the conversion. Might do it bit at a time slowly and re-co the donk with new head gaskets and timing belts before installation.

I really like the idea of a VSS in the dash cluster - the CV joint option would be loads easier but as we both agree - it would not cope with water and mud real well.

Still I plan to use a Gen 3 2.5 scooby SOHC donk - they are strangely more powerful than the ODHC donks and less bulky.

Just need to find a good local source that will sell me the donk, the computer, the ignition barrel and key and the main harness.

I am still wondering why a reversed coolant manifold is required - wasnt needed for by 2.7 scooby donk?




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posted on December 31st, 2013 at 04:04 PM



I'm actually not reversing the coolant manifold on this conversion, i have got the pipe that smallcar supplies for H4 turbo and H6 conversions. Shown here with pipe for the return(cold) side.

https://lh6.googleusercontent.com/-O9mu5M5uXkY/UsJcb1P08bI/AAAAAAAAAJo/aIV3Yk4zgKU/s800/P1050600.JPG




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posted on January 6th, 2014 at 11:20 AM



Brent,

I am defiantely not going for the reversed cooling manifold AM Autos can do that if they want but mine is aready set up for the original subaru design which has worked very well for the last 17 years.

I have made it my New Years resolution to get this donk swap done in 2014. I already have a few parts which have been cleaned up and painted and will be talking to Small Car as soon as I have cleared my Tax bill.

I will be following your install closely.

Cheers,

Scott




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posted on January 14th, 2014 at 12:10 AM



Great read Brent, thanks for all the info!
Who did you go with for the decoupler? And was it the US or German style?
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posted on January 14th, 2014 at 02:26 PM



The decoupler I'm getting from Daryl at AA Tranaxle, I believe it's the German style one. I haven't actually received it yet, he was waiting on parts to be made so I'm still waiting.



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posted on January 14th, 2014 at 04:54 PM



Cheers, had not heard of them before. Be interesting to see what you get.
I was looking at the Van cafe ones, but they are the US style (bushed shaft, not needle bearing).
What does it cost to ship each way (just ball park is fine)

I see the kits to do your own are cheaper, but they do not supply details of the machining (even though it appears simple)
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posted on January 15th, 2014 at 11:21 AM



Dunno if you saw this thread:
http://forums.aussieveedubbers.com/viewtopic.php?tid=93803&page=1#pid872593 

I was also looking at http://thelowestgear.com/product_info.php?products_id=113 
for a decoupler.
I will get around to it one day plus a lot of other things!
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posted on January 15th, 2014 at 03:50 PM



I sent Florian (the lowest gear) a couple of e-mails months back and got nowhere, sort of gave up on trying to contact him. Did manage to find his site for his real job through thesamba ( http://www.zolawindows.com/portfolio/reps/  ) but decided to go to Daryl as he was answering his e-mails.



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posted on August 11th, 2014 at 12:50 PM



Brent,

How is this build going?

Looking forward to updates....

I just had my AA transaxle decoupler fitted and tried a long freeway run and then an steep bush track run in 4wd and it worked well. Thumbs up for Matt's work from A transaxle.

Forget Florian - I dont think he does decouplers anymore and just makes windows (for houses - not computers).

How did you go with installing the Terrawagen Flares?




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posted on August 11th, 2014 at 06:56 PM



I've been meaning to update this. The decoupler has finally turned up, it was delayed by Daryl's unfortunate recent passing and sort of misplaced. The delay was understandable and I have been kept busy with other things anyway.

https://lh3.googleusercontent.com/-OZbBo1cfLPk/U-iEPROpBhI/AAAAAAAAARY/Je3TuMbzhI0/s800/P1050700.JPG
https://lh3.googleusercontent.com/-H4qcCX-jXn0/U-iETr80DuI/AAAAAAAAARk/PJ80WoJCsCA/s800/IMG_20140804_164229.jpg
https://lh4.googleusercontent.com/-yxLvMc7OoVE/U-iEUNnbzPI/AAAAAAAAARo/5j-vD6-sXpQ/s800/IMG_20140804_164249.jpg




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posted on August 11th, 2014 at 07:54 PM



I've been sidetracked by the beastie on the right.

https://lh5.googleusercontent.com/-ss4dijQSkwI/U0D1-fFDF_I/AAAAAAAAAMs/AsD_T_aneLk/s800/P1050629.JPG

I went from this

https://lh3.googleusercontent.com/-CnARIop4rII/U0D2CgOcJ9I/AAAAAAAAANE/TmkKp4OkEuY/s800/P1050611-001.JPG

To this.

https://lh5.googleusercontent.com/-P6hYkiHbbxY/U0D1_pWaDjI/AAAAAAAAAM0/wQXLYs01SzM/s800/P1050627.JPG

But we couldn't get it to idle just right so attempted to adjust the valves. Bad sign when you stick a telescoping magnet down the pushrod tube and pull this out!

https://lh3.googleusercontent.com/-aoUaaasf3JQ/U-iOI5rHe7I/AAAAAAAAAR8/9Psw0rYkXDg/s800/P1050630.JPG

Head of the valve had taken some punishment as a result.

https://lh4.googleusercontent.com/-BTO-qZX_XL0/U-iOJvCFw4I/AAAAAAAAASE/6nbi1EsLkY8/s800/P1050634.JPG




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posted on August 11th, 2014 at 07:58 PM



Add to this cracks between the valve seats it was time for a change.

https://lh3.googleusercontent.com/-lLsgQQiS3EA/U-iOLDMG5TI/AAAAAAAAASM/Isk82zV4kqc/s800/P1050704.JPG




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posted on August 12th, 2014 at 06:43 PM



Successful viscous coupling test

https://lh3.googleusercontent.com/-UUyXondO8us/U-iOMRA1k_I/AAAAAAAAASU/hrubQN8_US4/s800/IMG_20140809_101301.jpg




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posted on August 12th, 2014 at 09:54 PM



Brent,

Im a bit confused (nothing unusual there) - was the valve issue with the original VW motor or the scooby motor?

Whee did you find that other syncro? Show us more pics!

Cheers,

Scott




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posted on August 13th, 2014 at 09:12 AM



Valve issue was with the original WBX motor, the other syncro I picked up locally.

Base model transporter, not a Telstra van as it has seatbelt mounts in the back.




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posted on August 13th, 2014 at 02:03 PM



Brent,

Nice collection

Do you know Hamish from Mackay way somewhere?

He has a Westfalia roof on an ex-telstra panel van with raised suspension and a bigger motor (2.5 VW donk I think) plus he has a green high roof monster truck with 31" tyres.

There cant be too mnay syncro nutters in your town.




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posted on August 13th, 2014 at 03:51 PM



Ran into Hamish along time back, probably 5 years ago before I had a syncro and was cruising around in my manx.

Didn't know he owned the green monster but I have seen it once on the road.

There is another syncro up this way that pops up now and again.




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posted on August 13th, 2014 at 04:17 PM



This is it.

Error
Sorry, you must be a registered user in order to download attachments.




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posted on August 13th, 2014 at 07:08 PM



I dont know that one - but it looks real good being a Caravelle GL syncro it has all the goodies including power mirrors I see.

I also know Bruce Black from Rockhamption with his 1.9 VW turbo diesel syncro of mid blue colour. They are such rare vehicles you usually spot them fairly readily.

Did you get the new scooby motor in the 88 syncro?




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posted on November 10th, 2014 at 08:23 PM



Back here again, to finally answer you question no the 88 is still motorless. I hasn't help that I pinched conversion parts to get my other syncro up and running.

But I have had some progress, picked up a poptop today. Needs a lot of TLC but fixable.

https://lh5.googleusercontent.com/-aDd1sqX8mQY/VGCDFl-aEfI/AAAAAAAAAX8/xEExxFLNtp0/s800/IMG_20141102_140446.jpg
https://lh4.googleusercontent.com/-csYkFxp10yw/VGCDMUoCybI/AAAAAAAAAY8/78ufM9VJ0-8/s800/IMG_20141110_123009.jpg
https://lh6.googleusercontent.com/--Hfcfa9F_XA/VGCDOWPItrI/AAAAAAAAAZE/HgV34SRad8E/s800/IMG_20141110_123018.jpg




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posted on November 10th, 2014 at 08:28 PM



Will have to do some mods to it because there is no way I'm cutting this big a hole in the roof of my synco.

https://lh3.googleusercontent.com/-gosWCZtUcrc/VGCDKm0cOSI/AAAAAAAAAY0/zN9Hn3CXrUU/s800/IMG_20141110_120434.jpg




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posted on November 12th, 2014 at 09:18 PM



Thats the same hole in my roof although a slight bit smaller as mine is a recent version of the camperize design and has a slightly different rear tray but still this conversion is great as it doesnt cut out the front safety cell and mine is still stiff even after a fair bit of off-roading up rocky trails and on corrugated dirt roads.

Im sure yours was a lot cheaper than mine to buy though.




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posted on February 20th, 2016 at 04:04 PM



Finally some progress after doing conversions on two other vans. Sump, headers and engine mount on it way from Smallcar to replace the ones I borrowed for the other conversion.

Decoupler finally installed, think I will spend more time plumbing in the switch than it took to install this.

https://lh3.googleusercontent.com/-w7QaIPGmMfY/Vsf_kUnUlFI/AAAAAAAAAog/-TX8au4ihxI/s800-Ic42/P1060035.JPG


Engine is half prepped.

head gaskets, timing belt, water pump, coolant bypass, crank and cam seals are done. Waiting on the sump, headers and mount to turn up. EJ252 running EJ251 injection system with 105K km on it.

https://lh3.googleusercontent.com/-Xl1ONVvPrNQ/Vsf_lcQjS_I/AAAAAAAAAoo/_BmgRyxNSgg/s800-Ic42/P1060036.JPG




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posted on February 28th, 2016 at 04:30 PM



Well the sump and engine mount turned up on Friday so some work could get done.

Smallcar seem to have changed the way they make their pickups and have gone to a brazing process.
https://lh3.googleusercontent.com/-cucexJrwuAg/VtKOp_g9D6I/AAAAAAAAApM/v1_bDn-l43g/s800-Ic42/P1060042.JPG


Had to do the usual clearance around the water pump.
https://lh3.googleusercontent.com/-8DiriFOIQv4/VtKOr2vRqAI/AAAAAAAAApM/Br3S_fmbeAw/s640-Ic42/P1060050.JPG

But this is different, never had an issue here before now. Sump overlaps here and sits on the oil pump, had to shave it back so it was under the plane of the sump.
https://lh3.googleusercontent.com/-T7HA_bIgcsI/VtKOzqbYRsI/AAAAAAAAApM/oIXc5TiHBrM/s800-Ic42/P1060040a.jpg


Installed
https://lh3.googleusercontent.com/-1s5atquqXO4/VtKOqz9aWwI/AAAAAAAAApM/NEXSyey10L8/s800-Ic42/P1060043.JPG


Engine mount was not as good as usual and was a little out. This pulled together but basically twisted the centre section a little. Paint is crap as you can see here. Bits were flaking off as I was pulling it out of the bubble wrap. Powder coated over unprepared steel.
https://lh3.googleusercontent.com/-U3UEVqLdjvY/VtKOs49I3DI/AAAAAAAAApM/gE4G1zLX9KY/s800-Ic42/P1060053.JPG




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posted on February 29th, 2016 at 08:12 AM



Check the sump for casting sand, I found a few spots hiding up under the lip. Also sections of the inside look like the are peppered with little black spots, again this is casting sand. Most can be removed with a good blast with an air gun and most of the rest with a scriber and air gun.



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Membermackaymanx
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posted on February 29th, 2016 at 05:54 PM



Here is the coolant bypass on this engine, seems every time I do an engine I end up with a different way of doing it.

Elbow on this end is from the power steering return line off a Liberty. There was a nice port off the coolant manifold just there in the background but it was too close to plumb in.

https://lh3.googleusercontent.com/-9-RiuJFDJ6k/VtP03lrseYI/AAAAAAAAAqE/B4ZIJcaPY7w/s800-Ic42/P1060055.JPG


Nice port here to come out of the manifold, put the temperature gauge sensor in here while I was at it.

https://lh3.googleusercontent.com/-tpig_GNhE0A/VtP03uQ8hWI/AAAAAAAAAqE/loRcnps8bYs/s800-Ic42/P1060059.JPG


Proper terminal for the sensor. Plastic cover can be scavenged off the earlier 2WD Hilux Utes.

https://lh3.googleusercontent.com/-hDugJ2gpo2o/VtP042QgqHI/AAAAAAAAAqE/y0EzTMeLi9Q/s800-Ic42/P1060062.JPG




Quote of the week
"Do I wish to send them to you again, nope, no interest can't be bothered really, to much hassle for little or no return."

http://www.vw-mplate.com/mplate2-18600.png
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