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Thread: transmission installation in a VW beetle

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    Default transmission installation in a VW beetle

    The transmission presently installed in my 1960 beetle is less than perfect and howls like crazy at highway speeds. The gears crunched between shifting and the throw bearing made moaning sounds when the clutch was depressed. Luckily I found this gent in Michigan US who had been rebuilding transmissions for a living for 40 years before retiring and now works from home. He has a cache of NOS parts to build a transmission from scratch. The best part is that he builds a transmission as per the customers specs..from mild to wild. I don't do any crazy driving but I still opted for a new 3.88 ring and pinion, new pinion bearings, new syncro rings, welded and honed 3rd and 4th gear, new axles and tubes with new axle bearings and a new throw-out bearing. All the parts mentioned above are new old stock genuine VW parts made in Germany as the Good Lord wanted them to be, all fitted in a new later model transmission IRS case converted to swing axle.

    I am including pictures here but caution you to refrain from drooling on the keyboard please.I realize its pure p*rn for those looking for a half decent transmission to install in their VW's.

    I brought the transmission when it was done but the local VW mechanic wants $600 plus tax to install it in the car! Now I have seen it all done and there are tons of videos on Youtube but it still gives me the shivers when I think of the job ahead. However I am not going to pay anyone $600 plus 13% tax (and that too is a ball park figure given the approx. hours it would take..the final figure could well be a lot higher)

    I have the car on stands in the garage and have started with removing the wires. Even though there are not a whole lot of them but I am not taking any chances and have labeled them to remind me of their location when its time to put everything back together. (hopefully in a few weeks time.) I'll take pictures where ever possible and share with you the progress in the days / weeks ahead.

    Please wish me luck. I have a feeling i'll need lots of it.


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    Did you pick up the axle boots and the axle seals? Those went fast as the ones available locally last from a few weeks to a max of a few months. Again, if you have a spare tranny, I suggest you take that to Kahlid for a rebuild. This way if he spots anything else in there..like a fork or a gear that needs to be replaced I can send you just that from here. Once done you'll have a rebuilt tranny with you to install whenever you pull the engine out to replace the seals. (pulling the engine is half the work when replacing the tranny) Did you pick up the transmission mounts I sent? You can see a picture in this thread. You need to pull the engine out to replace those too. It is recommended to go for all of these jobs in one go. A good pair of tranny mounts reduces the engine vibration that is transferred to the car so worth considering.

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    Quote Originally Posted by nmshaikh View Post
    Did you pick up the axle boots and the axle seals? Those went fast as the ones available locally last from a few weeks to a max of a few months. Again, if you have a spare tranny, I suggest you take that to Kahlid for a rebuild. This way if he spots anything else in there..like a fork or a gear that needs to be replaced I can send you just that from here. Once done you'll have a rebuilt tranny with you to install whenever you pull the engine out to replace the seals. (pulling the engine is half the work when replacing the tranny) Did you pick up the transmission mounts I sent? You can see a picture in this thread. You need to pull the engine out to replace those too. It is recommended to go for all of these jobs in one go. A good pair of tranny mounts reduces the engine vibration that is transferred to the car so worth considering.

    I did pick up the Axle Boots/Axle Seals/Gear Seal and I already had the New Tranny Mounts including the Cone mount, in my stash. So I guess I can get ahead with rebuilding Tranny any moment from Khalid since the Synchronizer Rings are also available with @Romano right now as well as have the NOS German Clutch Throw Bearing and New Brazilian Fork, Shift rod Nylon Bushing & Boot, and Coupler Bushing available with me.

    It is rather a perfect time to start rebuilding the spare transmission and replacing the one on Patina when the flat four goes down for engine comparetment seals (which would be around May since I am waiting on the Bell Housing Seal to arrive).

    Thanks for the poke on getting the spare transmission re-build. Would get onto it asap.

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    Quote Originally Posted by nmshaikh View Post
    I may decide to take Billo for a long drive (and I mean LONG!) next year so all the attention at this point might save me some trouble later. Stay tuned for more news.<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com<img src=" /><o:p></o:p>
    And could this LONG journey be back home?

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    Quote Originally Posted by reezvaan View Post
    And could this LONG journey be back home?
    Still planning but yes thats the idea..Plan to make a stop on my way at the VW museum in Wolfsburg

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    Quote Originally Posted by nmshaikh View Post
    Still planning but yes thats the idea..Plan to make a stop on my way at the VW museum in Wolfsburg
    Well well well, now then this could be a journey of a life time and that too with the memories of stopping over at Wolfsburg museum with a piece of history to pay the tribute.

    Do keep us posted how this plan turns out to be.

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    Smile

    Quote Originally Posted by reezvaan View Post
    Well well well, now then this could be a journey of a life time and that too with the memories of stopping over at Wolfsburg museum with a piece of history to pay the tribute.

    Do keep us posted how this plan turns out to be.
    You'll get a ring-side seat

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    Quote Originally Posted by nmshaikh View Post
    You'll get a ring-side seat
    Are there any left which are not booked yet? Lol!!!

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    Quote Originally Posted by nmshaikh View Post
    No problem..its the least i can do from my position of advantage. BTW I just found some fuel filters that are made in Israel. How many of the members would find them 'Kosher' for use in their cars? (The other option is filters made in India as Bosch does not make them anymore.)
    i'm easy with such stuff, afterall the beetle is the ultimate "Nazi wagon",.. so we shoudln't be picky about using israili parts.

    anyone who wishes to argue with me on this point should ask themselves if they drink coca cola etc before hand.
    1. A car is only worth what someone is willing to pay for it, 2. Resale wont save your life in an accident, 3. Genius has limits, stupidity has none, 4. Never argue with an idiot, they will bring you down to their level & beat you with experience, 5. Growing old beats the alternative -- dying young! 6. انّا للہ و انّا الیہ راجعون

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    Quote Originally Posted by Storm View Post
    i'm easy with such stuff, afterall the beetle is the ultimate "Nazi wagon",.. so we shoudln't be picky about using israili parts.

    anyone who wishes to argue with me on this point should ask themselves if they drink coca cola etc before hand.
    @Storm

    Thanks that you didn't say "Pepsi Cola etc.", else I could have taken it personal, lol.

    Ok then it seems Israeli Fuel Filters are going on our VDubs. @nmshaikh, shall we?

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    Or the Indian ones are better?

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    I haven't seen either so I cannot comment. Will buy a small number, say 3 of each, and send for trial. The quality of Bosch branded filters deteriorated when we started getting the Brazilian ones but did not have much choice so kept buying those. Now even they have stopped producing (or the sellers have stopped buying fromthem in the US) so only the Israeli and Indian available.

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    It started raining in the wee hours of the morning and has been raining like it does in the monsoons! the forecast for tomorrow is no different, in fact the forcast is for some snow..Joy!. It clears up on Monday but on Tuesday we get hammered with another storm coming our way from the Midwest.
    The only good thing I can think of associated with this rain is that it washes away all the salt that was spread on the pavement in the winter.
    I guess, It'll be another week or so before I can finally take Billo for a test drive.

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    Quote Originally Posted by nmshaikh View Post
    It started raining in the wee hours of the morning and has been raining like it does in the monsoons! the forecast for tomorrow is no different, in fact the forcast is for some snow..Joy!. It clears up on Monday but on Tuesday we get hammered with another storm coming our way from the Midwest.
    The only good thing I can think of associated with this rain is that it washes away all the salt that was spread on the pavement in the winter.
    I guess, It'll be another week or so before I can finally take Billo for a test drive.
    At least there are no post rain puddles of mud.

    Have had been there mud, like we have here, you would have found yourself waiting for many more weeks before you could have taken Billo for a test drive.

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    almost non stop rain.... damn the April showers that supposedly bring May flowers.. I was hoping I'll get to test drive the car before the Boss arrives in a couple of days..

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    Quote Originally Posted by nmshaikh View Post
    almost non stop rain.... damn the April showers that supposedly bring May flowers.. I was hoping I'll get to test drive the car before the Boss arrives in a couple of days..
    Time for some Pakoras. When it rains here in Pakistan constantly, people prepare Pakoras to enjoy with Tea while having a sit down in verandas enjoying the pouring. I am sure you would remember something similar from good ol' days

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    Quote Originally Posted by reezvaan View Post
    Time for some Pakoras. When it rains here in Pakistan constantly, people prepare Pakoras to enjoy with Tea while having a sit down in verandas enjoying the pouring. I am sure you would remember something similar from good ol' days
    Mujhey yaad hai zara zara...

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    QUESTION: How much is a B-job?

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    ANSWER: Here in Canada it is $487.03...

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    Finally the rain clouds lifted and it was a beautiful day with temperature rising to 16*C..spring finally..even if for a day as there is a 30% chance of rain tomorrow after mid day. I decided to take advantage of the dry and sunny day and test drive the car which as been in hibernation for a good 6 months plus. The engine fired on the second attempt and puttered for a minute or so before getting to its usual harmonic throb at idle...What joy to hear the melodious sound of a well tuned VW air-cooled engine!
    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com<img src=" /><o:p></o:p>
    To hear that sound I had prepped up the car during the days when rain prevented me from doing anything else. A new battery is in place, I drained the fuel tank and poured fresh petrol bought @$1.37 a litre...(and you think petrol is expensive in <?xml:namespace prefix = st1 /><st1:country-region><st1:place>Pakistan</st1:place></st1:country-region>!) Before anyone asks me what’s the significance of 'fresh gas' (when I use the term Gas, I refer to gasoline fuel commonly known as 'gas' in <st1:place>North America</st1:place>). Gas or petrol, when allowed to stand for a period of time starts to thicken or gel. I am no chemist to tell you the reason or logic but maybe the more volatile vapours manage to leave the liquid somehow leaving behind a thicker than normal liquid. The recommended practice is to leave very little gas in the tank when parking the car for the winter. The old or stale gas can play havoc in the fuel system i.e. the lines, fuel pump and of course the carburetor.<o:p></o:p>
    <o:p></o:p>
    I don't start the car at all in the winter. It is a popular practice in our part of the world to fire up the engine every so often when the car is going to be parked for an extended period of time. It actually does more harm than good for the engine. More on that another time.<o:p></o:p>
    <o:p></o:p>
    The engine warmed up nicely and feeling reasonably reassured I decided to take Billo for a spin. She accelerated fine and shifting of the gears was like 'Malai' I have never driven a brand new Volkswagen beetle but I am sure the transmission would not feel too different from the one I have in my car now. After all it was re-built with all NOS parts..right down to the smallest needle bearings!!!<o:p></o:p>
    <o:p></o:p>
    Approaching the traffic light I decided to slow down...but what! Why is the car not slowing down? The brake pedal was touching the floor. Frantically I pumped the pedal and managed to get some pressure built, downshifting to the 2nd and then the 1st gear while pulling the hand brake up all the way...<o:p></o:p>
    <o:p></o:p>
    Billo stopped just inches from the car in front!<o:p></o:p>

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    The light turned green and I moved with caution..my right hand would reach for the parking brake (and stay there) immediately after changing the gear while I scanned ahead for any reasons I may have to stop in an emergency. I tried braking again when the road was clear with the same results as the last time. The braking power was almost non existent and I could only manage about 20% with raid pumping and another 20% with the combined use of the parking (hand) brake and gears. I drove around the block and returned Billo to the safety of our driveway.
    <?xml:namespace prefix = o ns = "urn:schemas-microsoft-com<img src=" /><o:p></o:p>
    I checked the brake fluid reservoir and as expected it had the right level of brake fluid. The only other thing would be the brake bleeding. I had asked my neighbour to help me with the job and had him sit in the driving seat while I had bled the brake. I had adjusted the brake myself..first tightening it all the way then loosening it an equal two clicks on each side. I had adjusted the hand brake too so what could it be?<o:p></o:p>
    <o:p></o:p>
    I jacked up the car and turned the wheel with hand. It spun freely half a turn then slowed down the rest of the turn..clearly the brake shoes were not centred. It was the same situation on the other side. After the near disaster a short while ago I made a quick decision to seek professional help. Brakes are something I don’t recommend you monkey around with unless you are absolutely certain of your abilities. I have to admit I’ve flunked in that department royally.<o:p></o:p>
    <o:p></o:p>
    I called the mechanic who said he can accommodate me if I got the car over within an hour. The tow truck took 20 minutes to arrive and another 20 minutes later Billo was up on the hoist in the workshop. Undoing the axle nuts is a breeze if you are using an air tool. They took everything apart leaving just the brake cylinders on and then put everything back on, adjusted the shoes, torqued the axle nuts, bled the brakes, re-adjusted the parking brake, took her for a spin, came back and parked.<o:p></o:p>
    <o:p></o:p>
    10 minutes later I was handed the bill.<o:p></o:p>
    <o:p></o:p>
    Now back to the question I asked a short while ago.<o:p></o:p>
    <o:p></o:p>
    How much is a B/job? I meant to ask How much is a brake job? <o:p></o:p>
    <o:p></o:p>
    Well I found out first hand that it is $487.03..<o:p></o:p>
    <o:p></o:p>
    And stop smiling..cuz I am not!<o:p></o:p>

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