Jason:

If that is what you wish to accomplish, why not swap the tranny for the flipped Passat tranny … there’s a project thread or two on Brickyard or Samba about the conversion.

> On 03-Jan-2017, at 18:39, Jason <uberhare@GMAIL.COM> wrote:
> 
> Even with the tuning peak torque still seems to be coming in around
> 2000-2200 RPM.  I've been driving a Passat with the same engine for 4 years
> now, so I'm pretty comfy with the performance level.  I've also towed quite
> a bit with it (2500-3500 lbs) and still cruises nicely at @ 2200 rpm
> heavily loaded (6 speed manual conversion).   Even putting another Passat
> wagon on the car dolly (3500 lbs + 3500 lbs) cruised fine at 2200-2400 rpm
> on the highway.   My cargo trailer is 8 feet tall, the mileage suffers
> heavily but my cruise speed does not.
> 
> I'm pretty confident the 4.14 will be ok, it's more longevity I'm concerned
> about.  It might just eat bearings every 4-5 years - which I could accept.
>  TDI's don't like the high revs as much as IDI's when it comes to fuel
> mileage I've found.  The Whitestar just did 500 miles last weekend and
> cruised happily at 75-80mph the whole trip :)   It's best highway Vanagon
> I've owned yet, also the first one I've had oversized tires on (205-70-15).
>  It will be our summer time daily driver/highway cruiser and will likely
> not get heavily loaded that often.  If the TDI will cruise @ 2600/75mph
> I'll be happy.  If was going IDI or ALH I'd likely use the 4,57.
> 
> Jason
> Uberbus
> 
> 
> 
> On Tue, Jan 3, 2017 at 11:18 AM, Dennis Haynes <d23haynes57@hotmail.com>
> wrote:
> 
>> My experience with the VW Diesels including the TDI is limited but I have
>> seen them. Here in New York we follow the CARB and conversions of any type
>> are restricted. We are not allowed any of the VW Diesel products from 2002
>> through 2006. We just don't see many Diesels here.
>> 
>> As for your gearing choice I think you are going a bit too tall. The 300ft
>> lbs is a high state of tune and that peak is around 2,400 rpm from what
>> I've seen. As such I think you want to get near that torque peak just above
>> 55-60 mph where wind resistance starts becoming the load. I would also
>> re-think that state of tune. While it works short term for hatchbacks and
>> sedans keeping that engine under sustained load/turbo boost is not good for
>> long engine life or emissions. Also there is nothing in that transmission
>> that will take that torque for any period of time. I would suggest the 4.57
>> R/P with the ratios you already selected.
>> 
>> Dennis
>> 
>> 
>> 
>> 
>> -----Original Message-----
>> From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
>> Of Jason
>> Sent: Tuesday, December 27, 2016 2:37 PM
>> To: vanagon@GERRY.VANAGON.COM
>> Subject: Re: 094 5 Speed Kit
>> 
>> I was looking at using the following gear set:
>> 
>> 4.13 final
>> 4.11 1st
>> 2.33 2nd
>> 1.48 3rd
>> 1.02 4th
>> 0.70 5th
>> 
>> This would make 1st a regular gear - which I have no issue modifying the
>> lockout.  The shift pattern would be the same as my LT, which works well.
>> The drop from 3-4 and 4-5 is about the same with this choice (1250 rpm).
>> In fact the factory diesel 5 speed (DX) uses the same gear set with a
>> 0.765 5th.  I'll be using a 2.0TDI with around 300 ft-lbs torque, so it
>> should
>> handle the .70 without issue.   Cruise at 70mph would be 2600 RPM with my
>> current tires.
>> 
>> There are a few threads on thesamba where people mention the Weddle kit,
>> but no one has posted anything first hand.  I suspect GoWesty is using the
>> Weddle gears to build their 094 5 speeds (
>> http://www.gowesty.com/product-details.php?id=4332).   The 091/1 is
>> essentially the same box as 094, making it easy to convert with the new
>> gear set and end cap.  Add the diesel 50 degree bell housing, and I'd be
>> good to go! (Albeit a few thousand lighter in the wallet...)   By the time
>> I re-gear the 4 speed with a new R&P and 4th, I might as well do the 5
>> speed I think.
>> 
>> Jason
>> Uberbus
>> 
>> 
>> On Tue, Dec 27, 2016 at 1:58 PM, vw_van_fan_Mark <madvws@cox.net> wrote:
>> 
>>> If you expect to use 1st a lot then you may want to remove the need to
>>> push down to clear the lockout. If you go with the 4.13 then more 1st
>>> use is probably where you will be.
>>> 
>>> Don has the odd early diesel 5 speed gearing, with his 5th about the
>>> same as an ordinary 4spd wbx 4th gear. His 1st is much lower than the
>>> wbx 1st so he seldom needs it and uses 2nd instead. That early 5 speed
>>> was meant for the 48hp early 1.6 diesel engine.
>>> 
>>> Your proposal to combine the tallest 5th option with the tallest r&p
>>> option means you should expect to have to drop down a gear more often
>>> so you may want to move 4th taller as well so the jump isn't so great
>>> between 4th and 5th.
>>> 
>>> Mark
>>> 
>>> Jason wrote:
>>> 
>>>> This page shows the available ratios:
>>>> https://weddleindustries.com/products/new-products/new-vw-094-5-speed
>>>> -kit
>>>> 
>>>> Looks like a viable option.  I've read it moves 1st down past the
>>>> lockout though.  I'd have to modify my shifter since that would drive
>> me nuts.
>>>> 
>>>> Jason
>>>> 
>>>> 
>>>>> On Dec 26, 2016, at 8:49 PM, Jason <uberhare@GMAIL.COM> wrote:
>>>>>> 
>>>>>> I am looking to build a 5 speed for a TDI conversion.   Does anyone
>> have
>>>>>> experience with the Weddle 094 5 speed kit?  4.13 final with 0.70
>>>>>> 5th
>>>>>> 
>>>>> would
>>>>> 
>>>>>> be nice!  Since I have to regear a transmission anyways, this may
>>>>>> be a
>>>>>> 
>>>>> good
>>>>> 
>>>>>> route:
>>>>>> 
>>>>>> https://weddleindustries.com/products/1000157/1005442
>>>>>> 
>>>>>> Jason
>>>>>> Uberbus
>>>>>> 
>>>>> 
>>>>> 
>>>> 
>>