T5 Crazy Conversion Project

[Golf Loon]

So I put the whole abs system in from the later ute, so the wiring will work out. As the ute was long wheel base, had to shorten the lines to the rear. Took the bits to pirteks who flared the ends and put the connections on for me. The van had a joiner on the lines, so utilised that to my advantage.

Had to take the covers off to do a neat job, so thought I'd just theorise where the diff would need to go.

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One bolt hole was there, welded in captive nuts for the other two

[Golf Loon]

Sitting Pretty

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Holes were in the floor for the one propshaft mount, once again needed to weld in threads.

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gonna need a shortened driveshaft section to fill in this gap

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[Golf Loon]

Will need to use handbrake setup from the ute to clear the diff and probably the exhaust system.

Covers underneath will be a good mix of van and ute.

In other news, firewall and wiring went back in sweet as.

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Engine mount arrived, the 4 wheel drive and 2 wheel drive ones are different.

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this meant we could then bolt the engine and box to the subframe and bolt it into the van.

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Sent the propshaft away Thursday to be shortened and went home.

[Golf Loon]

Friday we mounted up the front end. Inter cooler and radiator section fitted into the earlier T5 front and bolted it up.

Connected all the pipes and hoses, filled cooling system and plugged in wires. Have column inside loose but plugged in, put a battery on and tried to start it.

I have been involved in many conversions over the years and this is the only on that has ever fired on first kick of the starter, no priming of pump, no winding, over, just broom, starts and runs! Wow.

That has taken a week so far, now for the hard bits.

None of the wiring connectors inside for the van loom are the same ad the ute!!!!

Swopped over the front door modules and wiring, now have central locking and remote for the front doors, only 4 more to go and a sunroof.

Gary modified the ute loom to fit the van and run the rear diff wiring, also taillight loom.

got the propshaft back, only cost me $170 shortened and balanced! It fits haven't tried it yet.
rear shafts fitted straight into van hubs, all t5 rear hubs have provision for 4 wheel drive.
Had a factory built 4mo van in the shop today, compared the two, looks like I guessed the measurements right for the rear diff!

need to put the front hubs and big brakes on, dash and steering column inside, make lots of wiring work, covers, exhaust and handbrake underneath and lots more. At least it runs and the end is in sight!

[Rebuild]

Impressive, the amount of work and stuff.

So it's gone from a 2.5 174?? to a 4WD 2L 132KW ?

[Golf Loon]

2.5 R5 engine is 128kw and the 2l is 132kw

That is not the whole story, early R5 is a terrible engine, lots of quirks and crazy problems. Vw made it for 5 years then quietly dropped it

A conventional 4 cylinder engine with a belt is far more appealing to me as is the manual element.

It all comes down to useable power. 400Nm and 4 wheel drive should cover most of my towing needs, plus we can drive straight to Thredbo with no chains

[SnowMotion]

This is great build. Love it.

Yes, the 4motion 132kw transporter is fantastic as a snow car and tows really well.

[GTi Bhoy]

Awesome Matt.
Only you would do this.
Should be awesome.

[Sunny43.5]

Good job there hope you get the wiring sorted without too many headaches .

[Golf Loon]

Few progress pics

front going on



Engine looking snug

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Looking like a van again. Gary beavering away.



some wiring progress. Rear lights, front lights and blinkers now working, with some judicious splicing.

Kneebar and steering column in inside.

Central locking works on both front and both sliding doors. Just the back to go!

untold stuff to go back together. Will try to put hubs on tomorrow and bleed brakes so it can go on the floor and we can reclaim the hoist.