Syncro trans rebuild

FrankenSubySyncro · Posted: Mon Jun 02, 2014 5:46 pm Post subject:

How does the oil get from the pinion bearing inlet fitting to the pinion bearing bore and drilled pinion bearing? It looks like the main shaft needle bearing gets oil from the pinion bearing bore and drilled pinion bearing but didn't see any pics of how the oil gets to the pinion bearing bore.

gears · Posted: Mon Jun 02, 2014 8:04 pm Post subject:

The case is through-drilled from fitting to pinion bearing bore.

Image may have been reduced in size. Click image to view fullscreen.

Earlier in the thread there's a photo where I'm widening this inlet hole, to meet up with the oiling groove of the bearing.

The 3 hole are drilled with solid carbide drill bits, one per bearing. I think Eric's cutting the groove now, instead of grinding it (like the ones shown early in the thread).

Oil temp pick up is at the serial number, on main case.

I think Eric's photo shows a pick-up on the left side of the bellhousing.
Mine's on the right side ..

_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

vw-fan-flene · Posted: Tue Jun 10, 2014 3:09 pm Post subject:

zeohsix · Posted: Tue Jun 10, 2014 7:19 pm Post subject:

Eric's oil feed fitting is also now on the passenger side thanks to a little TIG welding. In fact Eric's 094 is actually sitting in his Westy for the 1st time since it was bolted to my 1.8T. Just ironing out a few more details with the engine mounts/exhaust then I can sit in van making Vroom Vroom sounds until I get little details finished.

For anyone wanting to groove a bearingthemselves, first make a holding fixture for the race.....buy a $125 custom ground carbide tool bit.....buy some carbide drills ( plan on losing or breaking at least one $25 drill bit per bearing)...have access to a vertical mill and lathe...measure and machine away or hit the " easy button " and contact Gears for his parts.......Paul thought long and hard about solutions to the 094 lubrication problems and I'm sure he can help you out if you have problems.
_________________
I'm Cheap! I'll build that Syncro Westy myself and save money but, my labor is "FREE" especially if I ever go to sell it! One thing is I will know the quality of the parts and labor that went into the build and rest better when I'm actually driving said Westy down the road!

insyncro · Posted: Wed Jun 18, 2014 4:54 pm Post subject:

Paul,
Looks like oiling mods are catching on Wink

boroko · Posted: Thu Jun 19, 2014 6:58 am Post subject:

OK, I'm envious...
insyncro, is that yours? Looks like doing the shaft drilling too.
Bo
_________________
'87 SyncroWesty: Smokey the Turtle, '85 SubiWesty: Chappie, '84 GTI, '86 GTI in full Rally trim,
previous: 2 Syncro tin tops, 2 Vanagons, 3 busses, 3 Ghias, 2 Jettas, a 411, a gas and a diesel Bunny and about 25 Beetles, one that only drove left.

insyncro · Posted: Thu Jun 19, 2014 7:06 am Post subject:

Not mine, an image shared from one of my European Facebook friends.

I know that a few around here are not into FB, but the coverage of Syncro specific and Vanagon specific upgrades is second to none.

FrankenSubySyncro · Posted: Fri Jun 20, 2014 5:14 am Post subject:

Dylan, can you provide a link to the facebook page? There looks like there is at least 4 locations where oil is being delivered. Do you know any details on this oiling design?
_________________
Syncronize it!
1987 Franken Syncro (converted 2WD auto)
2004 2.5 SOHC Subaru
F & R lockers, decoupler, SS, 6.17 R&P
Trans Cooler
EMPI race prepped 930 CVs and axles
Bilstein coilover front, rear ProComp MX-6066R shocks, 14" hypercoil springs
30x9.5 15" BFG Muds
Custom skid plates
Nose job (custom front bumper) http://www.flickr.com/photos/subyvanagon/sets/72157624970330925/

insyncro · Posted: Fri Jun 20, 2014 8:29 am Post subject:

Send me a friend request and I will add you.

Zeitgeist 13 · Posted: Fri Jun 20, 2014 9:19 am Post subject:

That Audi bellhousing with steel support bracket is pretty trick
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Casey--

'89 Bluestar ALH w/12mm Waldo pump, PP764 and GT2052
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Central Syncronizer · Posted: Wed Jul 02, 2014 4:00 pm Post subject:

[quote="gears"]Attention turns to the main housing once again. The goal today is to get oil to the dinky mainshaft needle bearing.

This pathetic little bearing is the result of the VW transaxle evolving to a larger pinion bearing, without spreading the shafts apart to accommodate a better needle bearing, too. They should have increased their center-to-center shaft distance from 65.65mm to 75mm.

Earlier transaxles had smaller diameter pinion bearings, paired with much larger OD mainshaft needle bearings. (I will insert comparison photo later).

Anyhow, it is what it is .. and because we want the ability to steel sleeve this case when it's serviced in 150K miles, we don't want to bore for a larger bearing (as is often SOP for high RPM installs). Besides .. we have a different thought ..

Great thread. Lots to learn here!

I've got a spare syncro transaxle I'd like to experiment with a bit to take SVX power with less worry.

One thing I'll be trying is a larger mainshaft needle bearing. There certainly is not a lot of room between the two shafts in the case to remove metal, but I'd like to bore it and put in a larger needle bearing. Is there a size that has been successfully used before?

cheers,

J
cheers,
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Ongoing restoration/maintenance of my syncro double cab (and soon Westy):

http://88syncrodoka.blogspot.com/

gears · Posted: Wed Jul 02, 2014 5:17 pm Post subject:

zeohsix · Posted: Wed Jul 02, 2014 6:27 pm Post subject:

Christopher Schimke · Posted: Wed Jul 02, 2014 7:48 pm Post subject:

zeohsix · Posted: Wed Jul 02, 2014 8:56 pm Post subject:

I don't recognize the VAG motor the starter is on the opposite side of the block from my AWP 1.8T but, I do see some square spacers lowering the front transaxle mounting point and they are giving up some ground clearance for the plumbing underneath ( hope they have a good skid plate! ) Can anyone tell me what the motor is? It also looks like the engine mounts lower in the chassis. Looks like it might be an Audi V6?
_________________
I'm Cheap! I'll build that Syncro Westy myself and save money but, my labor is "FREE" especially if I ever go to sell it! One thing is I will know the quality of the parts and labor that went into the build and rest better when I'm actually driving said Westy down the road!

Christopher Schimke · Posted: Wed Jul 02, 2014 9:13 pm Post subject:

It's a V6 TDI. The starter is in the original position for that engine. He made a custom bellhousing using a section of the Audi bellhousing which allows the use of the Audi starter.
_________________
"Sometimes you have to build a box to think outside of." - Bruce (not Springsteen)

*Custom wheel hardware for Audi/VW, Porsche and Mercedes wheels - Urethane Suspension Bushings*
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zeohsix · Posted: Wed Jul 02, 2014 10:56 pm Post subject:

I guess Im going off topic but, I like my ground clearances better than the V6 TDI 094. With the internal passages Paul used we accomplish a good oiling distribution without an inordinate amount of external plumbing and I like the KISS ( keep it simple.......) design of Pauls system. Here are some photos of my AWP 1.8T swap that is a work in progress but, for the first time since last year my T3 has a motor and transaxel installed! The value of my Westy has more than doubled in the past 2 weeks! Very Happy

Drivers side exhaust will be a little challenge but, so far so good

Passenger side you can see the blue aluminum AN cap on our oil draw from the differential area.....further ahead ( hiding past battery cable ) is the AN "TEE" fitting screwed into that feeds the pinion bearing pressurized lubricant. The piping to the Ggear housing is also taken off the pinion bearing feed fitting.

_________________
I'm Cheap! I'll build that Syncro Westy myself and save money but, my labor is "FREE" especially if I ever go to sell it! One thing is I will know the quality of the parts and labor that went into the build and rest better when I'm actually driving said Westy down the road!

Central Syncronizer · Posted: Thu Jul 03, 2014 12:17 am Post subject:

FrankenSubySyncro · Posted: Thu Jul 03, 2014 6:51 am Post subject:

Can you please post about any revisions you have made to the designs documented in this thread. Such as the oil feed location mentioned above. How many coolers have you installed? Are you now providing this service to paying customers?
_________________
Syncronize it!
1987 Franken Syncro (converted 2WD auto)
2004 2.5 SOHC Subaru
F & R lockers, decoupler, SS, 6.17 R&P
Trans Cooler
EMPI race prepped 930 CVs and axles
Bilstein coilover front, rear ProComp MX-6066R shocks, 14" hypercoil springs
30x9.5 15" BFG Muds
Custom skid plates
Nose job (custom front bumper) http://www.flickr.com/photos/subyvanagon/sets/72157624970330925/

gears · Posted: Thu Jul 03, 2014 10:03 am Post subject:

While there's absolutely nothing wrong with the way others are doing it, as Eric said, my efforts were toward an internal oiling solution .. more along the lines of what Herman did years ago (and in the direction that Porsche has taken in recent years). Eric's creation of the single tube linking main case entry point and low gear housing entry point have added to design elegance, and this attention to detail, especially in the G gear housing entry, assures that the transaxle location remains stock.

There is more to come, but we're not quite there yet. One little part we're working on will be quite useful as a "bolt-on" oiling solution that addresses the single most critical overheat area, 4th gear. A larger 4th gear bearing is NOT a solution. It isn't the bearing that's the problem (and the oiling grooves that VW now suggests to feed oil to this bearing are next to worthless .. at least when compared to true oil recirculation).

Certainly nothing more than a single cooler (with fan) is required. I'd even considered leaving the cooler out, just to prove a point .. but in retrospect, that seems rather silly, seeing as how we're already externally circulating the oil.

No, I don't really take on outside jobs .. I'm doing this in my retirement years. This is a hobby to me, and sharing all the details is what I've been doing with ANY knowledge about VW & Porsche transaxles that I've accumulated over the decades. Believe me, there is very little that hasn't been done before. I've just been lucky enough, and open minded enough, to have learned from many others.
_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com


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Syncro trans rebuild
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