My father and I have decided on a project for us to build together.
We really like the efficiency of diesel engines and love the newer smooth and quiet diesels.
We own a 2012 F350 6.7L crew cab long bed DRW, a 2011 VW Jetta 2.0L TDI and a 2002 Ford Ranger Edge 4.0L 4x4 automatic.
We want a small truck or SUV that is diesel, the 3.0L diesel Jeep was considered among some others but decided against.

The goal of this build will be high mpg with the same or more power than the Ranger currently has with the 4.0L gas engine.

We searched through different makes and models;
Chevy S-10 and Blazer
Dodge Dakota and Durango
Ford Ranger and Explorer
trying to find a good body with little rust.

We recently purchased a 2002 Ford Ranger FX4 with about 280k miles for $2000. The body is about a 7, some small dents and scratches and a little rust. The interior is about an 8.5, better than our Ranger with 160k miles. The frame, brakes, front and rear end are about a 7, it will need bushings and shocks but we will not work on that until after the conversion is done.

We searched through many diesel engines;
VT275
Cummins 4bt
Cummins QSB3.3
Kubota V2203
Mercedes Turbo Diesel engines
VW TDI 1.9L and 2.0L

We decided on the VW 2.0L TDI (engine id CJAA) for a few reasons;
Very smooth and quiet
Factory torque rating is very close to factory 4.0l Ford Ranger torque rating
Lighter than any other engine considered and lighter than 4.0l engine
Many upgrades available to increase hp and tq
Will pass emissions to 2011 (and maybe better) if we ever wanted to get a newer vehicle
These engines are readily available used for a reasonable price
There are many mechanics that know how to work on these engines
It is an On-Highway use engine

We researched using an automatic transmission but found it will be much easier to use a manual transmission, since neither of us has an issue driving a standard we decided to do this first as to not make this project to intimidating off the bat. We want to get it done in a reasonable amount of time and we can always make changes like this down the road.

Transmissions considered;
M50D-R1 (currently in the donor vehicle)
AX-15
NV-3550 Close Ratio
NV-3550 Wide Ratio
NSG-370

We decided on the NV-3550 Wide ratio for the following reasons;
Max torque is conservatively 300ft-lbs
Weighs 110lbs, about the same as the M50D-R1
They are readily available used, rebuilt, for a reasonable price
The gear ratios will work well with the TDI engine RPM power range.

Before starting the conversion we will take record some info/data from the stock Ford Ranger for before and after comparison. If you have any suggestions please let us know, so far;
Weight
Sound (in and out of cab)
The following will be tested loaded and unloaded, towing and not towing;
MPG
Acceleration at various speeds
Engine performance on hills

 

The donor truck

 

Very nice truck to start with! I will be looking on with great interest. I am wondering why you don't just use the trans that is already in the truck? We haven't had any issues with them behind the Kubota (we're making over 300#'s of TQ) and I've put well over 15,000 mi on mine that already had over 150,000 mi on it already. What adapter are you planning on using?

 

Nice! Link to your build? Are you using the V2203? What turbo? How loud and how much does it vibrate?

I didn't go with the M50D for two reasons;
The max torque rating is 240ft-lb and I would like to eventually mod this engine to be putting out about 330ft-lb at the crank
The gear ratio was not as good as the NV-3550

Right now I plan on making my own unless I can find one that I can buy, do you know of one?

 

Truck weights in at 4000lbs with under a quarter tank of gas. (I weigh about 160)


Filled the truck up and will see what MPG I get from everyday driving (city/highway mix)


Drove the truck a bit, got the RPM at 65 and 70mph (5th gear)



With my 250# dirt bike in the bed at 65/70 mph (5th gear) the truck did OK on hills, if I kept the throttle in the same spot the truck would slow down a lot, had to put my foot into it to keep it up to speed, probably should have been in 4th on some of the hills. Here are pictures of the truck and my 2002 4.0L Automatic (yellow) Ranger. My friend’s ATV (Banshee) in the back and he explained that that truck performed the same as mine.

 

My Dad ordered the NV-3550 yesterday from Smart Parts Automotive.

I found a 2010 TDI engine with turbo, wiring harness, ECU and some more about 2.5hrs away from me. We are going to check it out tomorrow morning. He says it only had 1500 miles on it when the car was wrecked and he just wanted it for building new motor mounts for a project of his. The pictures look great, hopefully it is as good as he says it is.

 

how much are they selling you the vw tdi engine?

 

I bought it for $3000 with the turbo, ecu, wiring harness and some other parts.

I have been working on another project so I have not done too much with this in the past week, but I will get back to it soon!

 

Been working on a different project (Yamaha Rhino open locking rear differential) so this one got put on hold for a bit. I did purchase the engine and it looks great, came with a lot of extra parts too. I need to send the ECU out to get it immobilized.





And we got the transmission in.



Engine and trans in the garage.



Ordered the bell housing yesterday so I can start mating the two!

 

Unfortunately things have gotten too busy for me to continue this project. Everything is now for sale. I have just put the engine and transmission up for sale and will put everything else up as soon as I get a chance. If anyone is interested please contact me and I will make you a great deal for it all!
Transmission: Unused Rebuilt NV3550 5 speed manual transmission
Engine: 2010 2.0L TDI Diesel VW engine complete turbo exhaust more!