1.9aaz moded to TDI in a Jeep.

[R.O.R-2.0]

Ok, I have asked this on several different jeep forums with no answer. Here is the deal:
I have a 2002 NV231 transfer case in this wrangler with a 21 spline input shaft. This 23 spline input is for sale http://www.ebay.com/itm/180984577476?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649
I will be mating the transfer to a NV3550 trans with a 23 spline output shaft. There are 4 different 23 spline input shafts for this transfer case, 2 different lengths and 2 different bearings...........What I need to know is if any of you know which input that is 23 spline will work with my parts? If any could help that would be great. I have local yards with jeep stuff so I think I could find one cheap and easy, or go with the ebay one that is pulled, but I just need to know what will work or not.


EDIT: Just found this, still am unsure of what I could get, but at least I have the differences laid out plainly. I should be able to do it once I pull the unit from the jeep now...at least. From what I gather it will be a late 23 spline with the narrow bearing and long input. Still if anyone knows what is up and could tell me I would take that.

http://www.novak-adapt.com/knowledge/np_nvg_input_gears.htm

if nothing else, use the GM output shaft.. its 23 spline, and made to work with the NV231..

my cousins 94 Chevy has a NV3550 and NV231 tc

[theman53]

I think I can, but the deal with the Jeep thing is there are different lengths. I figured you can run any of them, but to get it to match the trans without adding another seal is key. Plus mine takes a small bearing from what I have read...they couldn't make it easy. They should have had it to where all were the same length, same bearing, and all you had to worry was spline count. I will check into the chevy one, according to that site it maybe the same one as the jeep, as they used the same inputs in many different NV transfer cases.
See:
We've decoded most of the Jeep input gears and many are available for sale. The Jeep 231 transfer case is the main focus of our information here, but these gears interchanges can apply to:

NP231
NP233
NP241 (Chevy, Dodge, Jeep JK)
NP242
NP243
NP246
NP247 (always has 23 splines)
NP249 (always has 23 splines)

[theman53]

Found it without a doubt I know what is needed for my trans/transfer to work.

I need a 23 spline long input shaft with a 16mm bearing and the later style gear cut. Then I can put that in place of what my 4 cylinder trans ax5 21 spline input and it will work with the new 3550 trans.

So I don't forget again, http://www.novak-adapt.com/catalog/231_parts/np_231_parts.htm

This page is more about me not forgetting as it is helping someone else to search it LOL

[theman53]

K&N filter for this will be this one. I thought I had posted it earlier. I am using this thread for my parts list and a central place so I don't lose all my research.
http://www.knfilters.com/search/product.aspx?prod=RC-5182XD

[theman53]

I've been doing a lot of research, and this is what I've come up with:

1.) The Jeep Liberties came with NV1500 (between 2003 and 2004 with the 2.4L motors).

2.) The NV1500 shares the same case pattern as the NV3500/NV3550.

3.) The NV3500 shares the same case pattern as the Toyota R-series transmissions.

4.) The Toyota R151F bellhousing has the 22RE pattern on the front with NV3500 pattern on rear.

5.) Volkswagen TDI/TD to 22RE style transmissions adapters are common and relatively cheap (Rocky-Road, ACME Adapters).

Result: The ability to bolt on a Volksagen TDI/TD into a Jeep Liberty using:

TDI/TD engine | Common Adapter | R151F bellhousing | NV1500 trans

Anyone see any fault in my logic?

*********************
I ripped that off another forum and it was interesting to find. This is helping me as I have the NV3550 and now know that the Acme cheap adapter will work for what I need if I don't want to build it myself.



http://www.acmeadapters.com/store_engine.php

[R.O.R-2.0]

I've been doing a lot of research, and this is what I've come up with:

1.) The Jeep Liberties came with NV1500 (between 2003 and 2004 with the 2.4L motors).

2.) The NV1500 shares the same case pattern as the NV3500/NV3550.

3.) The NV3500 shares the same case pattern as the Toyota R-series transmissions.

4.) The Toyota R151F bellhousing has the 22RE pattern on the front with NV3500 pattern on rear.

5.) Volkswagen TDI/TD to 22RE style transmissions adapters are common and relatively cheap (Rocky-Road, ACME Adapters).

Result: The ability to bolt on a Volksagen TDI/TD into a Jeep Liberty using:

TDI/TD engine | Common Adapter | R151F bellhousing | NV1500 trans

Anyone see any fault in my logic?

*********************
I ripped that off another forum and it was interesting to find. This is helping me as I have the NV3550 and now know that the Acme cheap adapter will work for what I need if I don't want to build it myself.



http://www.acmeadapters.com/store_engine.php

NV3500 and Toyota R150/151 trannies have ZERO in common..

ive worked on alot of both..

the NV3500 in my cousins truck, and the R150 in my truck are 100% different in every aspect..

the jeep AX15 is IDENTICAL in every way to an R150/151 tho..

[theman53]

On the outside the nv3550 is identical to the ax15. I am just looking at getting this mess bolted together.

And you are comparing the NV 3500 to the NV 3550. The 3500 came in trucks, the 3550 was something weird that jeep did.

[R.O.R-2.0]

On the outside the nv3550 is identical to the ax15. I am just looking at getting this mess bolted together.

And you are comparing the NV 3500 to the NV 3550. The 3500 came in trucks, the 3550 was something weird that jeep did.

dude, the AX15/R150/R151 are made by Aisin-Warner.. the NV3500/3550 are both made by New Venture Gear..

totally different trannies, from totally different companies..

[theman53]

I know...The outside ex: bolt pattern, case shape, is the same. You couldn't interchange gears and shafts. I could care less. But if you wanted to physically bolt one onto the same engine I am saying it is possible, I am not saying that they are the same trans. 

I have done tons of research and it all ends up the same. The Jeep that has an AX 15 you can bolt an NV3550 to with no mods. So if it is like you say an AX15 is identical to a 151 then I will be able to use the acme 151 adapter for the NV3550.

[R.O.R-2.0]

I know...The outside ex: bolt pattern, case shape, is the same. You couldn't interchange gears and shafts. I could care less. But if you wanted to physically bolt one onto the same engine I am saying it is possible, I am not saying that they are the same trans. 

I have done tons of research and it all ends up the same. The Jeep that has an AX 15 you can bolt an NV3550 to with no mods. So if it is like you say an AX15 is identical to a 151 then I will be able to use the acme 151 adapter for the NV3550.

151 has different gear split.. has a lower first gear, and a MUCH higher price tag..

ok, i buy that the bell housing bolt pattern may very well be the same..

[theman53]

THIS is what I have needed. Our own 410 here is in this thread and in all honesty I am copying his design. I thought this is what I needed to get going on the adaptor. Turns out this was for the wrong Toyota. It was for a W56 trans and not the AX 15. Live and learn set back # 53...
http://forums.tdiclub.com/showthread.php?t=294454


All one ever needed to know about what swaps fit what... http://www.jeeps-offroad.com/showthread.php?t=4740

[theman53]

http://www.advanceadapters.com/pdf/nv_ebook.pdf

Page 54 reading for me about the ax15 to nv3550

also what I needed to find, Pre 1995 R150\R151 = 6.5"
1996 up Toyota R series = 7.5"
AX15 = 7.875"
87-92 Turbo Supra R154 = 7.25"
AR5 = 8.2"
MA5 = 8.2"
NV3550 = 7.875"
NV1500 = 8.6"
AX5 = 7.5"
Toyota W series = 6.5"
Toyota G series = 6.5"
Suzuki AG5 = ?

[theman53]

The NV3550 is a pretty robust gearbox.It shares all of its mounting points with the AX15 but, as far as I'm aware, shares no parts with it. So, any application that has an AX15, can take an NV3550 with no problems. Although the front case bolt pattern is identical between all of them (Toyota R, AX15, MA5, AR5, NV3550), the NV3550 has a unique front bearing retainer and shape. It may not be capatable with some aftermarket adapter plates.

More stuff I am trying to figure it out still...

[theman53]

I have a 92 xj as well and have a 1.9 TDI that's almost ready to bolt in.

There is many companies out there that are making TDI swaps a lot more easy and cost efficient.

I was able to get my ECU Flashed HP Boost/security eliminated along with a engine management harness that's down to 5 wires to hook up and the motor is running.

As far as mating the engine to the trans this wasn't that hard. 1/2" Alum. adaptor plate bolted to the engine with the bell housing pattern on the plate.

I'm using an AX15 5speed along with the stock clutch and flywheel. The flywheel is machined to the TDI offset crank bolt pattern. Along with the 4.0 starter.

I haven't figured out What I'm going to do about the drive by wire for the throttle or the motor mounts, and of course cooling

I found this info, so that tells me that I can make the crank spacer 1/2" under the Transmission spacer. Still tons of work to do, but I will get it eventually.

I will post specifics on this as it seems everyone that has done this before says they will sell a kit when done, but NONE do. HPA motorsports is apparently but not for the AX 15 and NV3550 yet, so it is pointless.

[theman53]

http://www.vwdiesel.net/forum/index.php?topic=30436.msg273237#msg273237

I may have to use this later, if I do I want to be able to find it.