Manual transmission rebuild - TDI

strawhouse · Posted: Wed Feb 19, 2014 8:02 am Post subject: Manual transmission rebuild - TDI

Trying to figure whether to rebuild my transmission in the Doka or get someone else to do it. How many TDI owners out there have done the rebuild by themselves with the taller gears? How many hours in were you and roughly what finished price range were you into?
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Pacifist with a gun

MarkWard · Posted: Wed Feb 19, 2014 8:16 am Post subject:

I have the skills, but lack the tools and experience, so for this project I went with AA. I had already run a 4.57 trans for a year or more and had crunched the numbers as to what I was looking to end up with.

I bought a spare diesel bellhousing and sent it to Daryl. I had him provide the core and order me a 4.14 ring and pinion. I had a not so great experience ordering something from Germany in the past and did not begrudge Daryl the chance to make a little money on the part and save me the headache. I also opted for a taller .77 4th gear only. He installed the oiling plates and his case modification.

Soon I had a rebuilt custom transmission sitting on my door step. Total was somewhere near $3400. Had I thought it through, I would have had the quaife/peloquin installed. Very satisfied with the results. I am at about 2900 rpm at 70 mph and the majority of my use is highway use. The .77 with that ring and pinion was too tall for the stock engine once I got out of Florida for the first time. I upgrade the stock nozzels to european stock nozzels and I have enough power for the taller gearing now. All of it was well worth it to me. Your results may vary.

Zeitgeist 13 · Posted: Wed Feb 19, 2014 8:20 am Post subject:

Yep, absent the proper tools, this really isn't a DIY thing if you want it to last. I'd be far more comfortable DIYing an automatic build.
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Casey--

'89 Bluestar ALH
'01 Weekender --> full camper
NEAT, no ICE.

Syncro Jael · Posted: Wed Feb 19, 2014 8:55 am Post subject:

hans j · Posted: Wed Feb 19, 2014 9:10 am Post subject:

I like my taller gears, 1.18 3rd and .73 4th on a 4.86 r&p
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1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181

MarkWard · Posted: Wed Feb 19, 2014 12:43 pm Post subject:

hans j · Posted: Wed Feb 19, 2014 12:53 pm Post subject:

It's probably around 3100-3200 with BFG 215/75-15. I don't remember exactly. It's nice and I can travel at freeway speeds if needed, but mostly I like the lower RPM at 60-65 mph. It's what Daryl recommended so I went with it. I was considering taller gears but even what I went with raises the EGT, especially on hills (mountains here).
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1986 Canadian Syncro Westy TDI - 1989 Syncro Single Cab - 2001 Audi S4 - 1981 VW Caddy ABA - 1980 VW Caddy EV - 1973 VW T-181

MarkWard · Posted: Wed Feb 19, 2014 1:00 pm Post subject:

Han's thank you, so I was close. We get only so many days vacation and it takes a solid 2 days to leave and come back to Florida. No way around that. Per day, we shave about an hour of time behind the wheel running 70 to 75 mph. Maybe we can slow down once we retire. I am hoping to find a taller ring and pinion for the front diff some day. I am also watching the subaru AWD thread with interest. The completed syncro camper tdi conversion is a long ways off, so I have some time. In fact lots of time. Thank you


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