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coolairX2
Samba Member
Joined: September 08, 2003
Posts: 485
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 Posted: Thu Jul 10, 2014 6:18 pm Post subject: Shop to rebuild a split Transmission in New England |
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So my transmission on my split which was rebuilt by a well known shop in Europe has broken. It only has 6k miles on it, but I have no expectation of warranty as it has been a number of years ago and I am on a different continent. Would have expected many years of trouble free miles but such is not the case.
Just want to drive my Split again before the summer is over.
Anyway, I am looking for anyone in the Northeast who has the experience and desire to work on it. I have talked with local transmission shops but they are not too eager to work on it. Not quite sure what is wrong with it but the wheels only turn two rotations before they stop.
Fitting a later model trans seems to be problematic due to the nose cone issues but would consider fitting a later model just to be able to enjoy my Split again. If someone could give me a lead on a mount that is actually available.
-Craig |
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VWLady
Crazy VW Lady
Joined: March 13, 2004
Posts: 3866
Location: Twin Cities, MN
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| Posted: Thu Jul 10, 2014 6:42 pm Post subject: |
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Check with John Henry. He was looking for someone to go through his transmission.
I have a place here in MN that did the one for my 49. |
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AlanInMass54
Samba Member
Joined: August 29, 2003
Posts: 1112
Location: Massachusetts
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| Posted: Fri Jul 11, 2014 4:33 am Post subject: |
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| I know a guy in CT that has worked on VWs forever and told me he can work on split cases. Is yours a no synchro only on first or a full crash box? |
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coolairX2
Samba Member
Joined: September 08, 2003
Posts: 485
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| Posted: Fri Jul 11, 2014 7:36 am Post subject: |
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| AlanInMass54 wrote: |
| I know a guy in CT that has worked on VWs forever and told me he can work on split cases. Is yours a no synchro only on first or a full crash box? |
Mine is a full crash box no synchro's. |
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mandraks
Samba Member
Joined: November 28, 2004
Posts: 7125
Location: Lawrenceville, Ga
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| Posted: Fri Jul 11, 2014 11:02 am Post subject: |
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just to satisfy my curiosity, what actually breaks in a crashbox transmission? I have never had a transmission fail for me, so i never got to look inside one.
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Uli
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'53 3-Fold Oval, L35 Metallic Blue, looking for a narrow hatch panel |
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AlanInMass54
Samba Member
Joined: August 29, 2003
Posts: 1112
Location: Massachusetts
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| Posted: Fri Jul 11, 2014 11:17 am Post subject: |
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| I just spoke to my friend in CT with the shop, he's done split cases but never a crash box. He said he's sure he could do it but would have to get a look at to give an estimate to rebuild it. He's a great guy and been doing VWs for many years so I wouldn't hesitate to deal with him. If you're interested I can get you his info. |
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Low Bräu
Samba Member
Joined: December 12, 2003
Posts: 346
Location: Merritt Island, FL
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| Posted: Fri Jul 11, 2014 1:34 pm Post subject: Re: Shop to rebuild a split Transmission in New England |
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| coolairX2 wrote: |
Fitting a later model trans seems to be problematic due to the nose cone issues but would consider fitting a later model just to be able to enjoy my Split again. If someone could give me a lead on a mount that is actually available.
-Craig |
Find an early bus nose cone and split case for the time being. I'm rebuilding a 58 split case gearbox right now for my 52 because I know when I tear into the crash box its going to be long ordeal locating parts to fix it. Split case parts are difficult enough to find. Sounds like something in the diff or axle may have broken. Any funny noises, clutch working ok???
_________________
Independent German Auto
671 Fern Drive
Merritt Island, FL 32952
(321) 449-4665
Specializing in repair and maintenance for Porsche, BMW, Mini, Audi, and Volkswagen.
1952 Standard Beetle
1960 SO-23 Westfalia
1961 L-380 Turkis Deluxe Beetle
1985 Vanagon Country Homes Camper (work in progress - EG33 swap) |
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coolairX2
Samba Member
Joined: September 08, 2003
Posts: 485
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| Posted: Fri Jul 11, 2014 1:50 pm Post subject: |
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| AlanInMass54 wrote: |
| I just spoke to my friend in CT with the shop, he's done split cases but never a crash box. He said he's sure he could do it but would have to get a look at to give an estimate to rebuild it. He's a great guy and been doing VWs for many years so I wouldn't hesitate to deal with him. If you're interested I can get you his info. |
That would be great. I would rather deal with a VW guy. I understand I would have to drive it down to him but I can do CT.
Send me a private message with the details
Thanks |
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coolairX2
Samba Member
Joined: September 08, 2003
Posts: 485
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| Posted: Fri Jul 11, 2014 1:59 pm Post subject: Re: Shop to rebuild a split Transmission in New England |
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| Low Bräu wrote: |
| coolairX2 wrote: |
Fitting a later model trans seems to be problematic due to the nose cone issues but would consider fitting a later model just to be able to enjoy my Split again. If someone could give me a lead on a mount that is actually available.
-Craig |
Find an early bus nose cone and split case for the time being. I'm rebuilding a 58 split case gearbox right now for my 52 because I know when I tear into the crash box its going to be long ordeal locating parts to fix it. Split case parts are difficult enough to find. Sounds like something in the diff or axle may have broken. Any funny noises, clutch working ok??? |
Finding an early bus nose cone is the issue. I can imagine that those are as hard to track down as parts for the tranny. Any leads would be appreciated 
Clutch is working fine. I can roll forward exactly two tire rotations and either wheel will just stop. At first I thought the drum was catching on the emergency brake lever. But no such luck it is something internal that is stopping the rotation. I have not driven it much for fear of making it worse. |
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Bruce
Samba Member
Joined: May 16, 2003
Posts: 17685
Location: Left coast, Canada
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| Posted: Fri Jul 11, 2014 2:42 pm Post subject: Re: Shop to rebuild a split Transmission in New England |
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| coolairX2 wrote: |
Finding an early bus nose cone is the issue. I can imagine that those are as hard to track down as parts for the tranny. Any leads would be appreciated
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http://www.thesamba.com/vw/classifieds/detail.php?id=1581002
This type of bus nose cone will allow you to install a 53-60 synchro 2-3-4 gearbox into your split.
If you want to install a 61 and later full synchro contact Rancho in CA. They have a custom nose cone that uses the stock split rubber donut mount
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usariemen
Samba Member
Joined: August 28, 2004
Posts: 1745
Location: Germany
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| Posted: Fri Jul 11, 2014 3:54 pm Post subject: Re: Shop to rebuild a split Transmission in New England |
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| coolairX2 wrote: |
Finding an early bus nose cone is the issue. |
This is such a bus one.
You see the red arrow? The deepness there is the only difference to a split beetle cone. As deep as in the cone of a 2,3,4 synchronised beetle cone.
Take a cone of a split, get that hole machined deeper and you have what you need to run a later gearbox in your split.
Or take the split cone as it is and ad a standard oval crash box. It bolts right together.
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VWLady
Crazy VW Lady
Joined: March 13, 2004
Posts: 3866
Location: Twin Cities, MN
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| Posted: Fri Jul 11, 2014 8:25 pm Post subject: Re: Shop to rebuild a split Transmission in New England |
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| usariemen wrote: |
| coolairX2 wrote: |
Finding an early bus nose cone is the issue. |
This is such a bus one.
You see the red arrow? The deepness there is the only difference to a split beetle cone. As deep as in the cone of a 2,3,4 synchronised beetle cone.
Take a cone of a split, get that hole machined deeper and you have what you need to run a later gearbox in your split.
Or take the split cone as it is and ad a standard oval crash box. It bolts right together. |
That is the dimension that controls the preload on the pinion shaft. I don't think that would be the smartest thing to monkey with.
The only differences between a crashbox and a partial syncro transmission is the syncro on 2, 3, 4th gears. All the rest is remarkably similar. If the mechanic can work on a partial syncro he can certainly work on a less complicated full crashbox. |
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johnshenry
Samba Member
Joined: September 21, 2001
Posts: 9417
Location: Northwood, NH USA
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| Posted: Fri Jul 11, 2014 8:35 pm Post subject: |
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Craig, I sent my '51 tranny out to Arizona tranaxle after getting some recommendations from some hardcore vintage guys. Bill Capatch did the work. His son runs the business, but he still works on the "old stuff". Unfortunately I think shipping it out there and back cost about as much as the rebuild. ($700+). Bill really knows the old trannys though and although it is not in the car and driving now, I think he did great work....
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John Henry
'57 Deluxe
'56 Single Cab |
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EverettB 
Administrator
Joined: April 11, 2000
Posts: 71922
Location: Phoenix 602
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| Posted: Fri Jul 11, 2014 11:07 pm Post subject: |
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| mandraks wrote: |
| just to satisfy my curiosity, what actually breaks in a crashbox transmission? I have never had a transmission fail for me, so i never got to look inside one. |
I can't speak to a crashbox but I know on the split-cases the main shaft wears out.
I'm guessing a bunch of the gears get trashed from grinding it too.
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coolairX2
Samba Member
Joined: September 08, 2003
Posts: 485
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| Posted: Sat Jul 12, 2014 8:38 am Post subject: |
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Thanks Guys,
I think I have enough information to get the old girl back on the road. Hopefully this time the trans will last more than 6k miles
-Craig |
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usariemen
Samba Member
Joined: August 28, 2004
Posts: 1745
Location: Germany
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| Posted: Sat Jul 12, 2014 9:17 am Post subject: Re: Shop to rebuild a split Transmission in New England |
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| nlorntson wrote: |
That is the dimension that controls the preload on the pinion shaft.
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Yes, that is the edge that pushes against the pinion shaft bearing wich peaks out of the box body.
The preload will be adjusted by the gaskets between the cone and the body.
| nlorntson wrote: |
I don't think that would be the smartest thing to monkey with.
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Well at least there are not much things in such technics you should monkey with. But if you know what you are doing it has nothing to do with foolish try and error action.
Here is a post 1952 beetle cone on the left and the earlier mentioned bus cone on the right.
The bus one has the split style mount and the beetle one has the later mount.
The inside has the same dimensions.
The beetles with synchronised gears have the last shaft bearing looking more far out of the box body as the unsynchronised ones.
So in an export beetle the cone fits just as is and for the use in an standard with a crash box there was 7 Millimeter spacer added.
That way VW used up from the zwitter the same part for both kinds.
So, if you want to use an oval box in your split, you can choose a oval crash box simply with your split nose cone. It bolts right on.
Or if you want to use the synchronised oval box you have to find such a bus cone or get a split cone machined 7 Millimeters deeper at that edge and use it. That is the only difference between the split and that bus cone.
At least that is how I understood what an gearbox expert had explained to me.
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eurodub
Samba Member
Joined: August 05, 2007
Posts: 1321
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| Posted: Sat Jul 12, 2014 10:46 am Post subject: |
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thank you Carsten i was always searching for this info.
i have a split nose cone for a synchro gearbox and it does not fit. sadly, i don't know anyone to machine the nosecone for me 
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usariemen
Samba Member
Joined: August 28, 2004
Posts: 1745
Location: Germany
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| Posted: Sat Jul 12, 2014 11:35 am Post subject: |
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Most machine building workshops with milling machines should be able to do it. If you find one, ask me once more and I´ll recheck the dimensions and give them to you.
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Low Bräu
Samba Member
Joined: December 12, 2003
Posts: 346
Location: Merritt Island, FL
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| Posted: Tue Jul 15, 2014 11:05 am Post subject: |
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I have an NOS 211.301.211 nose cone and the depth is 10.25mm for the front pinion bearing. I don't think there is anything to fear about milling the bearing receptacle deeper. You have to measure how far the bearing protrudes and the depth on the nose cone when setting the end play for the shaft anyway. If it's not right you will catch it there and correct the issue. If it's too deep you can ad more shims, too shallow and you just have to cut it deeper.
_________________
Independent German Auto
671 Fern Drive
Merritt Island, FL 32952
(321) 449-4665
Specializing in repair and maintenance for Porsche, BMW, Mini, Audi, and Volkswagen.
1952 Standard Beetle
1960 SO-23 Westfalia
1961 L-380 Turkis Deluxe Beetle
1985 Vanagon Country Homes Camper (work in progress - EG33 swap) |
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PastDown
Samba Member
Joined: December 16, 2009
Posts: 130
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| Posted: Wed Jul 16, 2014 1:32 pm Post subject: |
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Really useful thread, I've got the same issue, I have two question:
So, if I've got this right, I need an early split screen camper nose cone, and get it machined 7 Millimeters deeper then a later oval synchronization gearbox will fit in my split beetle?
How much beating can a crash box take? It sounds awful and is it's causing a lot of damage when you don't get the gear change spot on.
Thanks |
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