1965 Volkswagen Type-1 (Beetle) D.I.Y. Project (o\_!_/o)

[reezvaan]

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[nmshaikh]

A well built tranny is half of an enjoyable ride on any car (other half being a quieter motor/suspension) and just to have a soundless, thuds/crunches free tranny adds significantly to the pleasure of a ride.

Those of you who have driven cars with echoing trannys (most of you would be familiar with the term "hissey ki goonj") which produce thuds/crunches while shifting gears would know what I am exactly referring to here.

I am looking forward to the rebuilding of this tranny to provide me both, the enjoyable ride and a mechanical satisfaction. My only fear when it comes to rebuilding this tranny is that when this tranny is disassembled, it might need some hard to find parts beside the ones we have provisioned for by now. If that would be the case, it would call for desperate measures for the desperate times (I strongly hope it doesn't come to that as I dont want my friends to suffer the pain for hunting down the damaged spares to rebuild it). Fingers crossed.

This transmission (the one being cleaned up as we speak) has not been tested. Right? From the look of it, it is a locally used transmission (the ones that are imported are not mud encrusted...dirty, yes, but not the same type of dirt.
It would have been better if we could test this first before opening it up. On the other hand the one in your car right now is tested and you are aware of any sounds, noises, crunches and thuds. These symptoms can be communicated to Khalid (the doctor) so he is aware of what to look for when he opens up the 'patient' for surgery. Ideally we should be able to change everything that looks doubtful...bearings, forks, syncros, even an odd gear if needed. Since we do not have that luxury in Pakistan we should know the problem areas and address those.

[reezvaan]

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[reezvaan]

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[nmshaikh]

All I could gather from your post is that we should get this tranny mounted on Patina first and test it for a run "as is" before we take it for a rebuild (so that we are in a position of knowing exactly what needs to be addressed)

OR

are you suggesting to unmount the one on Patina and take that for a rebuild instead and leave this one as is?

Both of the above options can be opted. And yes its a locally used Transmission as it came of the butchered 66 complete along with the whole mechanicals (suspension/motor/beam etc.)

I leave the sequence of the events to you but I'd fit this transmission (which is now clean and presentable on the outside at least) in its present condition and test drive it. This would give you an idea of its general condition. Meanwhile the transmission presently in patina be packed off (and I am sure would be cleaned meticulously like this one) for a rebuild. I am sending a packing kit for transmissions that is used when a transmission is taken apart. Romano already has one so if you are in a rush you can borrow from him. I have quite a few used but serviceable parts that I salvaged from Thom's recycling bin but can't send all due to weight issues. However if I know a particular part I can send just that either from my collection or buy new and send.

[reezvaan]

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[reezvaan]

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[Xulfiqar]

@AsadIshaque has been able to discover the true/proper sealants for rebuilding of our motors/trannys today. Here is the repost of the picture borrowed from @AsadIshaque's original post at https://www.pakwheels.com/forums/d-i-y-projects/154599-o-_-_-o-restoration-project-1968-vw-1300-beetle-deluxe-7

I hope that this find would eliminate any leakage worries from the rebuilding of our motors/trannys.

@Xulfiqar

I was hoping if you could list for all of us the probable uses/appropriate application of each of the above since most of us are novice when it comes to applications of such purpose-built sealants and dont really know what should go where. Your knowledge base/regular work experience with these can benefit all of us here. So please take some time out and detail out the application of the above sealants.

The threebond is used to seal the crankcase halves together, the shellac is nice for prepping paper gasket joints (a slight smear on the fire rings of the head gasket too)
The P-TX-2 sealant is good for mating pieces like the the oil pump to crankcase - its very slightly forgiving (do not expect it to seal large clearances)
Its also used on the washers of the head/barrel nuts and crankcase fasteners - just a dab - to prevent seepage.
The shellac is also a pipe sealant and can be used for oil cooler flange threads - just a dab please.
The coppaslip usually for spark plug threads or anything that becomes a nightmare to remove afterwards - like the starter mount bolts or the brake shoe adjuster threads
The threebond or PX2 can be used also to seal up any imperfections on the pushrod tubes where they fit in the crankcase and cylinder head.

A good advice is to use a slight amount of threebond on the outer parts of oil seals to take up any scratch or ovalling of a seal housing in such an old engine.

Use your imagination - and it'll make sense.

[reezvaan]

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[Xulfiqar]

What do you guys use to remove the trapped starter bushing inside the transmssion? The Golf also uses the same principle and I replaced mine quite easily with an 11mm tap, a bolt and a nut

[reezvaan]

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[Xulfiqar]

where Dr Ishaque got this stuff from - he couldve found the degreaser can, Nowadays it costs about Rs 2000/- (its packed in Pakistan by Sloan) and is supposed to be mixed with equal petrol - that stuff will cut through anything - even gloves and if you are not careful.

I would also buy some ATF - and liberally coat all parts - ATF has very good detergent properties - and cleans out nicely, then wash with degreaser, SHINY

[Xulfiqar]

The above mentioned bearing numbers would be quite easy to find in Karachi - I would simply stop at the SKF agency behind RIMPA plaza and buy the items. There is also a whole bearing market on Lawrence road where you can buy weird oddly sized bearings too.

[Xulfiqar]

I haven't seen any servicemen using any purpose built degreaser ever to remove the trapped starter bushing.

How did you cure it for entrapment?

degreaser???

The bushing sits in a blind hole in the transmission - and if you are not careful in removal it will fall in the bell housing - usually mechanics do not take up this repair job.

[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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[reezvaan]

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