TheSamba.com :: View topic

Tue Feb 14, 2006 7:27 am

what tools are needed?

I plan on doing the "nut weld" approach to taking of the plug

41mm socket and something to hold bar the drum in place

do I need something to tak one of the lower bearings off?

drums will not need a drum puller but someone I know needs one, where can I get one or how can I make one?

thanks

Tue Feb 14, 2006 8:27 am

the bentley manual has a list of tools that you need, although you can usually get away with slightly less than that whole list.

here is a nice photo series:

http://www.thesamba.com/vw/tech/reduction_box_rebuild/

Tue Feb 14, 2006 8:59 am

yes, I looked at hazetguys' photos: slide #76 shows a bearing puller - do I need that and where can I get one? If not what else can I use to get bearing out?

Tue Feb 14, 2006 10:10 am

You need to make a puller. Get 2 hex bolts at the hardware store 2.5" long (not 5/16", but the next size down) and nuts, grind off 2 opposite points of the hex bolt heads so it is a "T" shape, insert those in the bearing races, and turn 90 degrees, drill 2 holes in a piece of angle iron, insert threaded end of bolts thru it, place the angle iron over the axle end, and evenly tighten the bolts till it pops out.

When I did mine I also gave the bearing a good soaking in PB Blaster and let it sit overnight.

Tue Feb 14, 2006 12:14 pm

thanks b-uber!

is that the only specail tool I need?

Tue Feb 14, 2006 12:24 pm

Nothing special, but a some pry bars (sometimes screwdrivers are not strong enough), rubber mallet or dead-blow hammer, and brass punch are helpful for "persuading" the reduction boxes apart. I've only done small-nut boxes, so I don't know what else is needed for the large-nut ones. A punching bag is also good to have, it's a very frustrating job...

Tue Feb 14, 2006 1:42 pm

You can make a tool to push the stub axle out of the inner bearing, after you remove the peening nut. Get a narrow , thick piece of scrap steel, drill a hole in each end to line up with opposite holes (for spring plate) on the inside of the inner case, drill a hole in the center to line up with the end of the stub axle and put threads in it with a tap. Two spring plate bolts will hold the plate on the case, then screw in your large bolt in the center hole to push out the stub axle.
To remove the end of the axle from the ball bearing and to push the bearing back on, get a large socket that matches the diameter of the inner race of the bearing and screw a long bolt through the socket into the threaded end of the axle. If you don't want to get different lenght bolts, put washers between the socket and bearing and remove them as necessary.
To remove the ball bearing from the axle tube, put an axle or a pipe down the tube from the opposite end and bang on it.
Out of all of the RGBs I rebuilt or junked out, a lot of the bearings fit loose in the cases. For the ones I rebuilt, all I did was "knurl" the inner surface of the case where the bearing fits in. I hit a small sharp punch with a hammer and put alternating lines on the surface of the metal< which shoved up some metal>

Tue Feb 14, 2006 2:46 pm

Campy wrote: You can make a tool to push the stub axle out of the inner bearing, after you remove the peening nut. Get a narrow , thick piece of scrap steel, drill a hole in each end to line up with opposite holes (for spring plate) on the inside of the inner case, drill a hole in the center to line up with the end of the stub axle and put threads in it with a tap. Two spring plate bolts will hold the plate on the case, then screw in your large bolt in the center hole to push out the stub axle.

kinda like this:
http://www.thesamba.com/vw/forum/album_page.php?pic_id=253149
http://www.thesamba.com/vw/forum/album_page.php?pic_id=253148
http://www.thesamba.com/vw/forum/album_page.php?pic_id=253147

Mon Jun 16, 2008 8:05 am

RGB on my thing. I want to make sure they have enough oil. What's the allen wrench or hex size plug? Thanks Ron

Mon Jun 16, 2008 8:44 am

17mm allen head.
You can get a socket for that.

earlier (splitcase) trannies tend to have the plugs that take 19mm open end wrench.

Mon Jun 16, 2008 9:02 am

iamdonquixote wrote:
41mm socket and something to hold bar the drum in place

thanks

is the 41MM socket to be used on 36MM small nut or 46MM big nut???? it is kinda in between sizes.

Mon Jun 16, 2008 9:14 am

Thanks Clara, I thought I wrote 17mm somewhere before I moved. Just couldn't find the paper with my notes.

Mon Jun 16, 2008 10:01 am

You can also use a bolt with a 17 mm head in place of a 17mm allen head. Couple of nuts, and your done.

Mon Jun 16, 2008 1:10 pm

bill may wrote: iamdonquixote wrote:
41mm socket and something to hold bar the drum in place

thanks

is the 41MM socket to be used on 36MM small nut or 46MM big nut???? it is kinda in between sizes.
It is for neither axle nut.

In the big nut boxes there is a nut on the inner end of the stub axle. It is too small for a 46mm socket, and too big for a 36mm socket.
You have to pull the welsh plug off to get to it, and that nut must be off to remove the stub axle which must be removed to replace either inner bearing.

There are probably good pics in Hazetguy's tutorial (link above somewhere).

Thu Jun 19, 2008 1:25 pm

For the nut on the inside of the lower stub axle I used a 1-5/8 socket (which is very close to 41 mm). They are easy to find and relatively inexpensive. Worked fine.

Thu Jun 19, 2008 6:46 pm

caribbeanlivin wrote: RGB on my thing. I want to make sure they have enough oil. What's the allen wrench or hex size plug? Thanks Ron

Make sure to check tranny gear oil only at center section side plug. RGBs are downhill from a stock tranny so oil runs downhill....

Tue Jul 01, 2008 11:37 am

and since no one has said it...when you want to take off that 41mm nut and you need something to hold the stub axle from spinning...a VW flywheel lock fits PERFECT on the dowell pin closest to the stub axle and locks into the gears on the axle to tighten or loosen the nut. Am i the first to try this?

Tue Jul 01, 2008 12:25 pm

ppp wrote: and since no one has said it...when you want to take off that 41mm nut and you need something to hold the stub axle from spinning...a VW flywheel lock fits PERFECT on the dowell pin closest to the stub axle and locks into the gears on the axle to tighten or loosen the nut. Am i the first to try this?

Great trick, I haven't tried that before.