Builds Another Prado in Montana
- Thread starter AirheadNut
- Start date
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- Thread starter
- #102
I got that one on Craigslist for something like $100 with a broken auto feed arm (still need to get that fixed). My dad has one that is a junkyard rescue, but we broke the ACME thread trying to get it loosened up.
- Thread starter
- #103
Work on the Prado has been hit and miss lately (mostly miss). However, I have been able to get a few things done.
Mounted up a set of 235/85R16 Cooper Discoverer S/T Maxx tires:
Also picked up another donor R150f from a '96 T100, going to swap out the countershaft for the Dyna 5th gear install.
Modified the airbox to work with the new MAF for the TDI:
After I got the airbox put back together I tried it in the engine bay and discovered that the MAF overshoots where the turbo is going to be. Things are getting tight on that side! I may have to build a custom airbox instead.
Mounted up a set of 235/85R16 Cooper Discoverer S/T Maxx tires:
Also picked up another donor R150f from a '96 T100, going to swap out the countershaft for the Dyna 5th gear install.
Modified the airbox to work with the new MAF for the TDI:
After I got the airbox put back together I tried it in the engine bay and discovered that the MAF overshoots where the turbo is going to be. Things are getting tight on that side! I may have to build a custom airbox instead.
- Thread starter
- #104
Familiar territory, this is the 3rd R150 I've torn apart for this project 
The desired part:
Definitely some wear in this transmission, syncros and hubs have seen better days. 2nd gear:
3rd gear:
The desired part:
Definitely some wear in this transmission, syncros and hubs have seen better days. 2nd gear:
3rd gear:
GTSSportCoupe
2LTE abuser
Glad you're still working at this! You are now an R150 sensei!
- Thread starter
- #106
Installed a new timing belt and water pump today. After helping do the timing belt on a '96 Passat TDI a couple of days before this was a breeze! It took all of an hour and a half, rather than the 8+ spent on the VW.
At 100k mile intervals it will be a while before I need to do that again!
I've also been working on an alternative for the factory air filter housing that leaves space for all of the intercooler piping.
A fan shroud is in the works, too:
At 100k mile intervals it will be a while before I need to do that again!
I've also been working on an alternative for the factory air filter housing that leaves space for all of the intercooler piping.
A fan shroud is in the works, too:
- Thread starter
- #107
I've been chipping away at the long to-do list. More work on finishing up the exhaust manifold; I added the base for the riser that the turbo will sit on:
I also got to work making a turbo flange, starting with a crude cardboard template based off a Passat manifold:
The flange is made from 5/8x3" bar; I would have preferred 1/2", but I didn't have any on hand. It's going to take a while to drill out the center hole with a holesaw on the drill press...maybe I'll have to make a circle cutting attachment for the cutting torch.
I also got to try my hand at oxy/acetylene welding, and used the ubiquitous coat hanger for filler! I'm pretty pleased with the results, there is good penetration but no lumps on the inside of the pipe, unlike when I tried to MIG weld the pipes.
I also got to work making a turbo flange, starting with a crude cardboard template based off a Passat manifold:
The flange is made from 5/8x3" bar; I would have preferred 1/2", but I didn't have any on hand. It's going to take a while to drill out the center hole with a holesaw on the drill press...maybe I'll have to make a circle cutting attachment for the cutting torch.
I also got to try my hand at oxy/acetylene welding, and used the ubiquitous coat hanger for filler! I'm pretty pleased with the results, there is good penetration but no lumps on the inside of the pipe, unlike when I tried to MIG weld the pipes.
FJBen
SILVER Star
I agree on the VW timing belt being a pain. My DD is a 2000 tdi Jetta that I did the timing belt change about 2 years ago. What a pain!
- Thread starter
- #109
I’ve mostly finished the turbo flange. Cutting the big hole with a hole saw on my hand-crank drill press took the better part of half an hour and left me with a tired right arm. However, it did insure that the bit stayed nice and cool with frequent stops to clear out all of the chips.
- Thread starter
- #110
Big milestone this evening, the turbo is finally roughed in!
Had to make some wiggles in the riser to clear the intake manifold and get the right angle for the flange.
Unfortunately the turbo actuator now sticks straight up and hits the hood, but I’ve got some plans for relocating it.
Everything still needs to come apart and get finish welded, and I need to add a turbo support bracket, but I’m super excited to finally see the turbo in where it should be. Next step is to finish up the intake piping.
Had to make some wiggles in the riser to clear the intake manifold and get the right angle for the flange. Unfortunately the turbo actuator now sticks straight up and hits the hood, but I’ve got some plans for relocating it.
Everything still needs to come apart and get finish welded, and I need to add a turbo support bracket, but I’m super excited to finally see the turbo in where it should be. Next step is to finish up the intake piping.
- Thread starter
- #111
It’s been way too cold to work in an uninsulated garage, so not much has been done recently. However, I’m going to need to pull out the engine and transmission to swap in the new countershaft and 5th gear. I figure I should take advantage of the engine being out to clean up the firewall and add some new sound deadener/insulation. The factory stuff is looking pretty poor:
Ideally I’d like to just add some on top of what is already there rather than pull all of the lines off the firewall. What are people’s recommendations for a good insulation to use? Will I need to rip off what’s already there or is it possible to stick new on top of old?
Ideally I’d like to just add some on top of what is already there rather than pull all of the lines off the firewall. What are people’s recommendations for a good insulation to use? Will I need to rip off what’s already there or is it possible to stick new on top of old?
- Thread starter
- #112
Got some work done this evening, mostly working on the turbo actuator mounting and linkage. Made several bits out of scrap that was lying around:
Also had to put an ear on the old actuator bracket:
Also had to put an ear on the old actuator bracket:
- Thread starter
- #113
The (almost) finished product. I mounted the actuator upside down and on the opposite side of the turbo from the vane lever. The rocker arm on top seems to operate smoothly, even without washers.
Next up is a trip to the hardware store to get the various little pieces to hook up all the linkages.
Next up is a trip to the hardware store to get the various little pieces to hook up all the linkages.
- Thread starter
- #114
Final assembly of the turbo. There are some really tight clearances and everything has to go together in a very specific order.
I also finished welding up the exhaust manifold:
Now I need to take it to get the flanges machined.
I also finished welding up the exhaust manifold:
Now I need to take it to get the flanges machined.
- Thread starter
- #115
Well, this thread is way past due for an update. My summer was consumed by work, a remodel project and moving, among other things, but I'm finally ready to start work again and hopefully get the finishing stages of this swap knocked out. I've gotten a few small things done since I last posted here.
I made a bracket for the VW coolant expansion tank:
Pulled the engine and transmission out (again!)
And tore apart the transmission for the R452 5th gear swap.
At this point I ran into some problems getting everything to work, and summer took over. Had to move shop (not such a bad deal!) Huge thanks to my brother for letting me invade his space once again!
I made a bracket for the VW coolant expansion tank:
Pulled the engine and transmission out (again!)
And tore apart the transmission for the R452 5th gear swap.
At this point I ran into some problems getting everything to work, and summer took over. Had to move shop (not such a bad deal!) Huge thanks to my brother for letting me invade his space once again!
Is that a cement floor? Bet you don’t miss the gravel! 
- Thread starter
- #117
A cement floor AND a center post lift. Life just got a whole lot better. It was kind of novel to roll a couple of engines across the shop with the hoist.
- Thread starter
- #118
Work has proceeded pretty slowly since the last update, generally due to waiting on parts. A couple of weeks ago I passed a huge milestone by getting the transmission back together for the last time. Word of warning to anyone wanting to do the R452 5th gear swap on an early R150/151: just re-gear your diffs, it will be lots cheaper and save a ton of headache! I discovered that with the change in 1995 almost every internal part of the R150f was redesigned; I ended up having to use everything but the case and main shaft assembly from the donor transmission, and had to buy a transfer adapter from an HZJ79. Right now I'm waiting on a new transmission mount so I can modify my crossmember to work with the longer transfer adapter. The rear propshaft is at a machine shop getting shortened by 1.5", and I'm planning on using a spacer on the front to get everything lined up.
While waiting for parts I did this:
I wanted to keep the inside/outside thermometer this time around, so I cut out the housing where the altimeter was and fitted my double din Auber for pyrometer and water temp. I also made a new face plate that is going to be painted like the original.
This has also been consuming a fair bit of my time. New timing belt, water pump, alternator and rear diff rebuild. It's a 106 with 115k km on the clock.
While waiting for parts I did this:
I wanted to keep the inside/outside thermometer this time around, so I cut out the housing where the altimeter was and fitted my double din Auber for pyrometer and water temp. I also made a new face plate that is going to be painted like the original.
This has also been consuming a fair bit of my time. New timing belt, water pump, alternator and rear diff rebuild. It's a 106 with 115k km on the clock.
That transmission mod has turned into a lot of work for you. Never saw that coming. Sounded so simple when you first mentioned it.
- Thread starter
- #120
Definitely. The crazy part is if I had gone ahead and ordered the gears when I first looked into it, I would have had no problems at all. By the time I had spent a month debating and researching the early counter gear was NLA and I was stuck with the later one.
