So this is certainly an adventure and the biggest car project that I have bitten off -- converting my 02 EVW to 5-spd manual using the elusive 02G-AFL transmission. I have fielded a few inquiries as to how this was going and I thought I might start a small thread here to chronicle things as the project gets started. I've been sitting on the parts for over a year -- and finally have the right window to start working on the van. I will certainly get to the details of this, but I just want to start with an intro of sorts.
For years I sat on the sidelines, looking at Vanagons/Dokas and waiting for the "New Microbus" concept to come to fruition. With onset of children and the necessity of a people-hauler, it was actually Cole's original thread that inspired me to go Eurovan -- and specifically look at 24v-VR6 models. Once I saw the front end off the van -- I realized it was no more difficult to work on than any of the other VWs I've owned (all water cooled). Owning something built in this century is a little bit reasuring to my wife, whom I wouldn't want behind the wheel of "classic" car anyways (with concerns of safety, reliability, etc). I don't want to get into the pissing war of Vanagon vs Eurovan - clearly each has merits/detractions. However, I do believe that most people neglect to see how the Eurovan was actually a rebirth for the vw-van platform -- even Volkswagen itself likens the T4's succession of the rear-engine design to that of the Golf replacing the Beetle.
I've owned a good half dozen VW's leading up to the decision, so I was not alarmed to read that there are "some issues" with the model that scare others away. I figure almost all cars have issues -- what sets VW's apart (IMHO) is the dedicated enthusiasts who share their knowledge and impart wisdoms that build user communities. What did keep me a little hesitant - were the automatic trans repair stories - whether or not they are overblown - I don't know. I have never been keen on automatic transmissions -- so I was always thinking of swapping transmissions from the get go. Be it a mTDI or something else - I was dead set on changing it.
Now even though I'm in Canada (land of funky Eurovans) -- there is a noticeable shortage of long-nose vans and they are impossible to find. I passed on the opportunity to buy a local one owner, ultra-ultra-low mileage 02 EVW in my province -- but the price was close to $30k! I realized I couldn't stomach spending that much on something I would being looking to convert to a manual and started to look stateside for a good deal. In a whirlwind week of van shopping in Vancouver and Seattle - looking at 12 vans - I was lucky enough to find "Lucille" a Tornado Red EVW owned by van/bus enthusiast.
The moment I first saw "Lucille" drive across the parking lot -- I was smitten. In hindsight, and knowing her the way I do now -- I can safely say that she looked good from a far... Still, I was convinced of her potential -- and the lowest price 24v-VR6 EVW I had seen in while. Highway mileage at 225k and two owners - with some rust starting on the rocker panel, some banged up interior pieces. The right community-vibe from the owner sealed the deal. He loves vans and took pride in the EV (while also owning himself a Syncro-High-top) and had gotten Lucille ready to keep before deciding to sell -- putting on new 215/70/16 BFG ATs, Blistein HDs, a Yakima rack, an ARB awning, Pioneer double-din dvd player. To me it was good value on the extras . When I agreed to keep the van named "Lucille" he took another $500 off. Handshake, done deal.
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