Andy's Syncro Projects

Volkswagen Transporter Syncro

BEFORE: 'The brick' as purchased in July 2003 After: August Bank Holidy 2004 IOW

(Click here for info on this example.)

Improvements and other work carried out to date
Other work planned
Suppliers list
15" steel rims, BFG All-Terrains
At time of purchase the van was on the original 6Jx14 rims, and very worn Michelin X tyres of some kind. The van had a rather wallowing ride quality, which was attributed to the tyres (which did not appear to be LT-rated), and perhaps worn dampers (likely at ~94,000 miles). New OEM dampers at each corner were procured, and rim/tyre alternatives investigated. It soon became clear that there was a very limited choice of suitable LT or off-road tyres for 14" rims. Research showed that a popular upgrade on 14" Syncros is to 15" rims, which provides the benefits of wider tyre choice and greater ground clearance, whilst not requiring the bodywork modifications needed to fit 16" rims and tyres. It was also noted that many Syncronauts choose the BFG A/T and it appears these provide an excellent combination of performance, long life, and lower road-noise than some competitors.
  1. 5 off Mercedes 6.5Jx15H2 ET37 rim, pn: 210 400 02020
  2. 5 off BF Goodrich All-Terrain T/A 215/75R15 (LT-rated)
  3. 2 off aerosol cans Hammerite metal paint, smooth silver
  4. 20 off chrome-plated closed-head wheel nut
Replace Viscous Coupling
  1. Refurbished Viscous Coupler VW pn: 094 409 435
  2. Loctite liquid gasket thinned with alcohol
  3. Loctite blue nut-lock
  4. 2 litres GL5 synthetic gear oil
  1. 6 off Bonded rubber mounting VW pn:183 199 381 A
  2. 5 off M10 large penny washer (10.6x65x5) VW pn: 903 371 01
  3. 4 off M10x100 bolt
  4. 1 off M10x90 bolt
  5. 5 off M10 Nyloc nut
LT Mirrors
The stock T3 mirrors are mounted on a ball-joint which is notorious for coming loose and flopping about. There is no 'detent' position so if moved, returning the mirror to its correct position is time-consuming. Syncro 16's are commonly fitted with a 'truck-style' arrangement using a larger mirror unit fitted to a D-shaped metal arm supported by pivots at top and bottom. These are available from Europe at about £80 each, but a cheaper alternative is to use units from the LT, which are very similar (indeed the mirrors themselves are the same part number).
  1. Pair LT mirror arms including upper/lower brackets and plastic gaskets, from 'Just LT's' breakers.
  2. Pair LT mirrors, VW pn: 281 857 547 B
  3. Pair plastic bush, VW pn: 281 857 532 A
  4. Pair steel retaining clip, VW pn: 281 857 533 A
  5. 2 off M6x50 stainless steel cap head screw
  6. 2 off M6x20 stainless steel c/sunk socket head screw
  7. 8 off M5x25 stainless steel c/sunk socket head screw
  8. 8 off M5 steel 'Riv-Nuts' and insertion tool
  9. ~12cm length 25 x 3mm self-adhesive closed-cell foam
SA Grilles and driving lamps
Partly functional, partly cosmetic, the grilles fitted to South-African 'Microbus' give a distinctive, business-like look to the Syncro and set it apart from regular old camper-vans. Pic 1, Pic 2.
  1. Upper SA grille kit, including trim, badge, H4 driving lamps. Justkampers
  2. Lower SA grille, Justkampers
  3. 2 off double 40A relay ( £1.50 each from trade stand at a show)
  4. Wire, insulated spare terminals, sleeving etc.
Saab heated leather seats
Installing the seats

Alleged by JK listees to be a simple bolt-on operation, but after obtaining the seats it was clear that the Saab 'rails' were wider apart than the existing mountings on the body of the van. After some deliberations with my brother (thanks Ed !), it was realised that we could re-mount the Saab rails on the inside of the seat frame, and thus ensure they have the desired spacing to bolt right onto the VW mountings. The only loss is the driver-side height adjuster, which we don't need as the resulting position of the seats is about as high as you'd want 'em. (Very short drivers shouldn't consider this upgrade.) Pic 1, Pic 2, Pic 3.

  1. Pair leather front seats from 1990 four-door Saab 9000
  2. 2 off heating control unit for above, with wiring loom connector
  3. 8 off M8x50mm bolts
  4. 8 off M8x20mm screws
  5. 16 off M8 nuts
  6. ~26cm. thick-walled steel tube >8mm internal diameter.
  7. A quantity of 15mm plywood
  8. A quantity of black vinyl material
  9. Angle-grinder, hacksaw, files, drill & bits, jig-saw, staple gun and staples etc.
Wiring the seats

The heating elements are thermostatically controlled by the special control units, using sensors fitted inside the seats. The controls units have four positions, off and three heat levels, and they have the following connections (from a message on a Saab Forum):
 

2: +12V from the fuse box - Yellow wire
6: Thermostat - Blue wire
7: Illumination - White/brown wire
9: Ground - Black wire
10: Heating element - White/yellow wire


The wiring coming from the seat is as follows:
 

Thermostat - Blue x2 (one to control switch , one to ground)
Heating element - Yellow x2 (one to control switch, one to ground)
 
Trim panels

It was decided to fabricate a suitably-shaped trim to conceal the seat frame and slider rails at each side of the seat. Some 15mm plywood was procured, profiled to suit with an electric jig-saw, the edges were radiused, and they were covered in a flexible vinyl-coated material held in place with a staple-gun. These were bolted in place using tubular spacers to achieve the desired alignment. The trim panels also served as a convenient mounting for the heater control switches.

Replace worn-out front and rear dampers
  1. 2 off OEM equiv. of VW 251 413 031 C front damper, Sachs 110 337 or Boge 32-180-0
  2. 2 off OEM equiv. of VW 251 513 031 D rear damper, Sachs 110 338 or Boge 32-181-0
  1. 2 off M14x1,5x80 bolt, VW pn: N 040 165 2 OR
  2. 2 off M14x1,5x100 bolt VW pn: N 010 200 2
  3. 2 off M14 penny washer (15x28x2.5) VW pn: N 011 534 1
  4. 2 off Inner sleeve VW pn: 251 413 097 A
  5. 2 off Outer sleeve VW pn: 251 413 097 B
  6. 2 off M14x1,5 Nut
  7. 4 off M10x16 socket-head bolt
Renew front suspension components
When the front dampers are being replaced, an inspection will be made of the front suspension ball-joints and bushings. Those parts that appear worn will be replaced.
  1. 4 off Upper control arm bush, VW pn: 251 407 077
  2. 2 off Lower front A-arm bushing, VW pn: 251 407 183
  3. 2 off Upper ball-joint, VW pn: 251 407 361
  4. 2 off Lower ball-joint, VW pn: 251 407 187
  5. 2 off Radius rod rubber mounting inner, VW pn: 251 407 179
  6. 2 off Radius rod rubber mounting outer, VW pn: 251 407 175
  7. 2 off M18 Nyloc nut
VDO oil pressure, oil temperature and voltage guages
T3's had none of the sophistications of later cars such as the Golf GTi 'MFA', which provides useful engine-monitoring functions. Further, as the engine is rear-mounted the driver is somewhat distanced and less 'in-tune' with the state of the engine. It was therefore decided to add oil pressure and temperature guages.
  1. Set of VDO guages from mid-eighties Audi Quattro in original angled plastic binnacle
  2. VDO combined 5-bar oil pressure / 0.5-bar low pressure switch sender
  3. VDO sump-plug 150 degree C oil temperature sender
  4. M10 fine-thread male-female extender tube for VDO pressure sender
  5. Strip of aluminium to fabricate large P-clip to mount sender
  6. Strip of steel to fabricate mounting bracket for guages
  7. ~6m. multicore 'caravan' cable
  8. Crimp spade terminals, sleeving, screws, etc.
Propex heater
These things retail for ~£400. I was fortunate to come across a second-hand but unused 'Compact 1600' unit on Loot and got it for £200. It's a complete system, but is missing the thermostat and mounting brackets.
  1. Propex thermostat, mounting brackets
  2. 8mm copper gas pipe, fittings
Service rear differential lock
Adjust gearshift linkage
Baulky shifting can be alleviated by overhauling the linkages at the front (base of the gear lever), and rear (at the gearbox input arm). After gaining access, I greased these parts liberally with molybdenum disulphide grease. After reassembly, I found a noticable improvement, particluarly in selecting fist and second. The second phase of this work will involve renewing the bushes, and one of the protective rubber boots at the rear which has perished.
Stainless Steel screw kit
Dashboard Trim
The metal dashboard had suffered somewhat at the hands of one or more PO's, it had several holes drilled in it, and had had some vile wood decorative trim super-glued to it. When I pulled off this trim, some paint came away too leaving a rather tatty result. Several functional and cosmetic upgrades were therefore installed, which subtly transformed the cockpit:
Anti-rust treatment inside body panels
Treat rust around rear windows
Install Fire-extinguisher
Essential tools
Suppliers