'61 corner window westy campingbox

[Clara]

[mudbucket]

[campingbox]

I thought we were still talking about the beam leaf springs, not the brake springs. I have spares of them all.

I had the transmission this far apart, so I decided I'd take it a step further. I walnut shell blasted the case, and then Clara & I drove up to Gary Zinks place in Kent. Gary has been rebuilding transmissions since 1974, and is a super nice guy. I think everyone in the Seattle area should be using him.

We removed the R&P, and immediately decided to replace the side cover bearings with new ones.

Then we pulled off the front housing with the gears and set it aside:

Cleaning up side cover plates.

Then we set off to set up the ring & pinion preload:

With that done it was time to look at the gear cluster:

Some of the ~'60-'65 gears you can no longer get new synchro rings for, so these gears were replaced with the later type with new rings to match. Same ratio, just larger gear with bigger better working syncro rings.

Clara examining the slider gears. We ended up upgrading both sliders to the style with modified pockets to hold the gear in place.

Increasing the end play on 4th gear. Gary said the book spec is not enough.

Gary was very impressed with the double pinion roller bearing. He said this was the nicest one he has ever seen in 40 years - it still got replaced with a new one because it was worn out.

One of the shift forks was worn and the replacement was too long to fit in the box.

Shift fork adjustment:

Gary said the mileage is not original, that the speedo has turned over at least once.

[wcfvw69]

What a great post and thread. I love the detailed photo's of this transmission refresh. How terrific is Gary that he allowed you guys to look over his shoulder as he went through that box.

I get concerned with the age of these guys getting up there. So much VW expertise is wrapped up with these guys at or beyond retirement age. Let's hope they are mentoring and passing on their experiences to a much younger generation to keep our VW's on the road for decades to come.
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Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[zuggbug]

Greg, if I didn't know in better, I would assume you plan to drive the wheels off this bus.

I am really enjoying all the detailed pics and posts.

Thanks for sharing, I know it takes time.
_________________
SOUTHERN INTEGRITY AIRCOOLERS
58 15 window
56 westy

[sled]

[Clara]

[EverettB]

Cool set of photos, I love that stuff.

It looks like shift fork adjustment but is being done on a different transmission casing?
The yellow one?
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[easy e]

[campingbox]

Yes, that is his shift fork adjustment jig. He has a whole rack of different transmission cases to adjust all of the different types. VW made special tools for each different type transmission, but they essentially work the same as a cut away case.

I had a few requests for info to get in touch with Gary - here is his contact info:
http://www.garystransaxles.com/

Here is how it looked when we left Gary:

I made this tool to hold the axle in place and keep the fulcrum plates from slipping behind:

I have never had that happen but I have seen it happen to other people so I figured I'd be careful.

It's pretty much ready to go back in the bus:

It would be faster to put the reduction boxes together while it's on the stand but I always find it difficult to get the transmission into the bus without scratching the boxes or the spring plates. It's still a struggle either way, but at least like this it's about 75 pounds lighter.

[guatebus]

This thread gets more awesome every time I check it!
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'64 standard microbus
'69 deluxe microbus

[campingbox]

After Linds brake failure a few years back, new metal lines throughout seem to be standard fare.

Also re-welded the clutch tube.

The reservoir is leaking, need to change that too.

Also cleaned up the wheels front and back and added new tires and trim rings.

[House]

Awesome wall of tools!

[KombiMadness]

[Clara]

Working on the tubes before the tranny goes back in.

Used the shop vac to clean out the heater tubes from the back. It is a bit easier with the transaxle out of the way.
Then decided to do the blow and suck, the shop vac blows from the back and sucks from the front. Unfortunately I didn't bother with getting the suction in place and blew from the back and grit went all over the cab. Even though I thought it had been sucked out.

So got the suction in place and cloths over the defrost vents and along with a bunch of garbage this guy came out of the heater tube:

This was pulled out of the heater tube, not too bad. Better now than while the bus is driving.:

This is the shop vacc hooked up at both ends on Cuddy's bus:

There is a hole in the heater tube at the curve under the corner window, I could poke my finger in from the top and push the grit in there so it could be sucked out the slightly enlarged drip hole under the tube. Need a pic of that.

Then with a clutch cable doubled over roto rootered out the shift rod tube from the back. Then from the front. Then did the shop vacc from both ends on that, and a bunch of rusty grit came out.

Next step will be to pull an oily rag through the shift rod tube to thoroughly oil and grease it up on the inside, before installing a freshly painted nice shift rod ... not the original one which was rusted.
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The Obsolete Air-Cooled Documentation Project http://oacdp.org/

[66busman]

I love the push/pull vacuum setup. I'll be borrowing that trick, for sure. Keep up the good work!
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'66 SO-42
'73 Bay
'75 Type 181

[Major Woody]

[wcfvw69]

Eww.....
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[arthurnugen]

[campingbox]

More progress. Trans in and boxes done. Still have a bit more work to make it a roller again.

I reused all but two of the 6306 reduction box bearings. The two new ones went on the inside of the drivers side box.