Kind of looking to see if anyone has swapped a 4.0, 5speed, 4x4 ranger with a smaller diesel engine? If its been done I'd like to know what it would take or any ideas on what it would take.

 

Welcome to the forum

Yes, been done a few times, Google: Ford Ranger TDI swap

There is even a TDI adapter plate, but its not cheap, but for 4x4 it would be required since there are no 4x4 TDI transmissions

You would want to use a 2003 or earlier Ranger, as the 2004 and up changed to digital dash and required more work to do the conversion

 

Mine is a 2010 but its a 5 speed manual. Would that make the swap easier??

 

No, 2010 will be a PITA because computer and dash along with most modules are connected on a network they don't like changes
You will spend alot of time going thru wiring diagrams and trying to reprogram modules that may or may not work out

It would basically be a ground up build, pull out everything, all wiring and electrics, and then add back what you need to get the diesel working and then add back what you need for the dash instruments and other controls like wipers, exterior lights and ??

I would sell the 2010 and buy a 2003 or earlier with a bad engine and/or transmission and go from there, same Ranger looks wise just way easier to convert

 

I have a 3.9 cummins in my ranger; all mechanical engine...

 

Did you do the conversion yourself? What's your honest opinion of the truck with the 4bt (I assume).
I have considered doing that conversion to my 2001 4.0 when the motor is done. I know it would not be cheap but I sure like the idea. I just worry I'd always be working on it and chasing problems?

 

I did do it myself, you are correct with the 4BT. Overall I think it was a good swap, that motor just shakes the vibration on it no matter what it goes in is a lot. So it has a good vibration to the whole truck at about 45 MPH. I am also running 42" tires with the proper gears so going fast is not an option. Top speed is maybe 55 but from the outside the truck looks like its going to shake apart, inside it is what it is. A truck with a cummins on 42s, gears on 4 links. I think it rides good for what the truck is.

I could probably play with the gearing and make it better but for what I have set up wise I am happy. I actually haven't had any issues with mine. I got it out of an old bread truck, I replaced seals and all going in but no issues (knock on wood)

If I could of fit a 6BT in there I would.

 

I've got a 1999 B-3000 thats been lifted for about two years. Gas prices up here in Canada are gone through the roof because of the carbon tax and I pulled my truck off the road and am driving a TDI jetta because being an apprentice and having to gas up two times a week doesnt work well if you want to save some of your money. I've decided I'm going to TDI swap my truck and daily drive it because #1 driving cars sucks and #2 diesels are cool and 40 mpg is even cooler.

I'm probably going to be going with the 1999-2003 ALH since its pretty bulletproof, can make up to 180hp pretty reliably AND parts are cheap (Volkswagen wise at least). Not sure how I'm going to get the factory Ford trans to bolt up to the ALH without spending 1500 bucks on an adapter plate but I'm scouring the internet trying to figure out if theres a RWD VW that I can steal the transmission from. All and all I think it's going to be great when it's done.

 

The M5OD-R1(M5R1) manual transmissions used in Rangers are ENGINE SPECIFIC, so an M5R1 from a 4.0l won't fit on a 3.0l and visa versa, the bell housings are part of the main housing so are not detachable
So there were 4 different M5R1 housings made, 2.3l/2.5l(SOHC), 2.3l(DOHC), 3.0l and 2.9l/4.0l
You may find one type would be easier to build an adapter for, but never looked into that

Gearing wise it would be better to find a diesel transmission that would work, never compared ratios used in a TDI vs Ranger gas

 

Honestly I haven't thought about the gear ratios in the transmission at all until now that you mention it. I assume they would be pretty different. Admittedly I don't even know the final drive ratio in the transaxle of my Jetta. I just bought it because diesel was 20 cents cheaper per litre and my buddy owns one and loves his. I'm thinking a RWD Volkswagen TDI powertrain would be great but from what I've been reading, they don't exist. I had a feeling the VW van had a TDI in it but i seem to have made it up