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Alright, I've waited long enough and I'm going to shed some more light on my project(s) :ninja:

Here's the story; a couple years ago my father-in-law bought a 1991 Dodge Grand Caravan LE from the original owner. 300K on the original 3.3L AND A-604. Also, it's an AWD :thumb: It was some old guy that had it and although the clicks were high, it was in very good condition. He had it rust checked for almost 10 years of the van's life.

So he buys it. First his wife drives it then my wife starts driving it. As luck would have it the A-604 took a shit last winter. Since we all had other vehicles we just parked it until there was a need to fix and drive it again.





Fast forward to today. Right now my DD is a '93 Duster (3.0L 5-speed of course :p). It works okay with my one son because he can hop in and out of the rear seat. However, later this year there will be another addition to the family. The duster won't cut it...plus FWD traction is horrible in Winnipeg winter's. I could just have a winter beater and keep the duster for summer, but I have another car that will take over summer duty. Then it hit me, the van with the blown transmission! Sure, I could simply rebuild the transmission and start driving it, but where's the fun in that? I don't mind the 3.3L, but I want something I can mod. Okay, 3.0L it is...and since I'd be swapping in a 3.0L, a 5-speed is definitely going in at the same time.

But now what to do with the AWD? Pfft, make it work of course :cool: Thanks to R&D from others I am much more confident that I can successfully adapt the AWD PTU to the 5-speed case. The nicest part of the whole swap is that I don't have to screw around with ANYTHING in the back. No custom driveshafts, modified gastanks, fabricated rear suspension...none of that. The van will see DD duty and will not be a race van (although I am contemplating an m90 in the future).



This is where I am at today. OMG do I hate pulling 3.3L's I always end up stripping half the engine apart just to get the bloody thing out. I can do a 3.0L in literally half the time. So the engine/transmission/PTU are out. Wiring is out. Clutch pedal is in (thanks again Ed). I have a 3.0L van harness ready to go in plus the rest of the 5-speed parts. Engine/transmission are coming from the donor Daytona below (psst, if anyone wants to buy 3rd gen daytona parts minus the drivetrain I'll be listing it soon).



The Daytona engine will be out this week-end and depending on time/weather I may do the first fitting minus the PTU. Things like power steering lines and exhaust I'm not totally sure on. Also I want to work out any electrical gremlins or anything else related to the 5-speed swap before taking on the AWD. Then I'll pull it out again and finish everything for the PTU. Should mostly be brackets, adapter, and diff modifications.

Phew, anyways...I figure if I dedicate a thread to this it'll help keep my butt in gear. Plus I'm always looking for input and other ideas. One idea I was floating around was switching to a 6-puck clutch. I have a feeling the first time I dump the clutch at 5k it'll be toasted. I bet that van (it's pretty much loaded) weighs over 4000lbs with me in it.

Any thoughts? Am I crazy? Like/dislike?
 

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Discussion Starter #2
Make it happen. :)
Hey, I was expecting a snarky anti-3.0L comment from you, lol :p

Timeframe to completion is expected to be under 3 weeks so expect quick progress. And please, if anyone wants to see specific pics of the PTU, adapters, etc remind me because I will probably forget to take a picture!
 

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I LOVE IT!!!! all wheel drive 5 speed!!! whats not to love about that!!!:thumb:
 

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Can you document the PTU to A543 mating? Thats one of the few big things i'm not 100% on for when i get to do the AWD on my duster
 

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On the pedals, No problem!

So are you going to use the Daytona's electronics and wiring?

Good to see the project moving! Keep the pictures coming!
 

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Wow awesome project. Definitely keep it updated. This awd 5 speed thing has peaked my interest
 

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Discussion Starter #9
On the pedals, No problem!

So are you going to use the Daytona's electronics and wiring?

Good to see the project moving! Keep the pictures coming!
I didn't realize that 3rd gen daytona's have no plug at the firewall (my 2nd gen did :confused:) so I went and grabbed a 3.0L 3-speed harness from a different Caravan to use instead.
 

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Discussion Starter #11
Man please tell me the passenger front fender on that daytona is dent free. I want I want.
I was wondering if you'd lurk in here and start asking about it :p I think it's pretty clean but I haven't done a thorough inspection yet. IIRC it's the same color as yours too. I'm about to head out to the garage and take it off...if you're interested in grabbing a bunch of parts off me I'll make you a sweet deal :cool:
 

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Discussion Starter #14
Nice. What about the CSX? When does she get AWD?
Oh, she will see AWD in the future. That'll be next winter's project :TD2:

In other news, pulled the donor engine/transmission from the daytona last night. Found something awesome. I pull an axle and fluid starts pouring out. No big deal...until I saw it was RED! Yes, the idiot who had it before filled it with ATF instead of 5w30 oil :eek:mg:
 

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No waiiii ATF in an MTX car? Sounds kinda silly.

Project looks very sweet! Will there be enough room in there for the Ho' when she comes in there next month? :p

What are the differences with how the A604 mates to the PTU compared to the A568?
 

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Discussion Starter #17
That was the factory recommendation for many years.
Well I'll be...you learn something new everyday :eek:mg:

No waiiii ATF in an MTX car? Sounds kinda silly.

Project looks very sweet! Will there be enough room in there for the Ho' when she comes in there next month?

What are the differences with how the A604 mates to the PTU compared to the A568?
Yep, Daytona will be scrapped in probably 2 weeks.

A-604 is a bolt up for the PTU, any MTX requires modification. I'll outline everything once I get there.
 

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Sounds good! I'll likely be doing the 5 lug and brake swap in a couple weeks. Engine still requires reassembly, but that will wait until I get parts back from paint.

Excited to see where this AWD goes!
 

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Discussion Starter #19
Quick update: Bobble strut bracket hits the AWD K-frame, stock 3.3L exhaust about 2 inches too long (although angle looks bang on). Not a big set-back but a setback nonetheless.
 

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Discussion Starter #20
Heh, so remove the bobble strut bracket. :)
Have you machined the bearing races in the trans to get the AWD diff to fit yet? Have you tried to get the PTU to fit up along the back side of the 3.0 block?
Hehe, that's one way to go about it...

Races, not yet. I've got some parts on order so right now I'm working out the kinks for the 5-speed swap. Once parts come in I'll be pulling it again and doing all the machine work at once.

PTU, I haven't done a "bolted-in" check yet but as it stands there's over an inch of clearance in the back and I still haven't removed the bracket from the block --> transmission. No grinding has been done to the 3.0L block and I'm 95% sure nothing like that will have to be done.
 
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