Manual Transaxle oil cooler bung fittings (homebrew)

[Sodo]

Goofing around with the TIG welder today. I made a set of 8AN bung fittings for the case that a guy wants to add the pump & cooler system to a trans thats in the van. These fittings are made from VW bungs obviously. The drain bung won't work on a Smallcar bellhousing, pretty sure it's for a VW bellhousing only. (?) Weddle pump, cooler and filter come with 8AN fittings.

I tapered a stainless pipe into a nozzle and aimed it at the mainshaft bearing. Current transaxual wisdom holds that 4th gear and the mainshaft bearing are trouble points for big engines, driving fast (65mph+). Because they are so far above the oil level they can overheat and sometimes even melt the plastic needle bearing cage inside the gear. It's a good location to squirt your cooled oil.

You'd have to mark the fitting, and add some teflon tape and "clock it" to aim at the (1/8") gap between 4th gear and the Mainshaft bearing. The nozzle took a lot of time, was a challenge. Inspired by the nozzle in Gears' thread.

Nozzle welded inside.

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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[newfisher]

Nice work!
How much?

[flomulgator]

AWESOME!
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She's built like a steakhouse, but she handles like a bistro!

[Sodo]

[dobryan]

Cool. Thanks for posting this.
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Dave O
'87 Westy w/ 2002 Subaru EJ25 and Peloquin TBD

"To travel hopefully is a better thing than to arrive." Robert Louis Stevenson

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[hdenter]

Sign me up for two sets!

Hans
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'79 triple white convertible bug
'84 sunroof vanagon
'85 weekender

[hdenter]

Sign me up for two sets!

Hans
_________________
'79 triple white convertible bug
'84 sunroof vanagon
'85 weekender

[Syncro Jael]

Will that still work with the SA oil plates?

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1987 Syncro Westfalia Hightop - NAHT
Subaru EJ25 Forged Frankenmotor, Triple Knob.
Jael = (Mountain Goat)

[Sodo]

I think so. You can see the two holes for the SA oiling plates it's pretty clear of those holes.

If pipe is centered over the "MA" of "GERMANY" it aims right at the lower opening of the bearing.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[Syncro Jael]

[Sodo]

I made another set.

4th gear and the bearing spin in the direction to gobble up the blast of oil. Straight pipe aims at the little oil-gathering channel below the bearing. The maximum possible angle points at this channel.

A little more angle would be preferable, but that rib (between GERMANY and the bunghole) limits how far the pipe can wobble off-axis as the bung is screwing into its threads.

Here's the set.

Then I decided to bend it a little. It wasn't easy. Next time I'd bend a longer piece of tubing THEN cut it after bending.

This angle is better. If it was just a little longer it might be better, but I don't know if it's gonna collide with stuff (such as the SA oiling plates). I don't have the oiling plates. But you can see the screwholes for the plates that Weddle put in this case.

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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[SteveMc]

A bored through tube fitting would allow greater flexibility in directing the oil flow.
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1986 Transporter Single Cab Syncro

[ALIKA T3]

Great looking fittings man!!

I'm actually looking into producing the In and OUT fittings as well, more like a bushing and an AN8 banjo fitting. It's a pita to have somebody do it, nobody cares about small batches .
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
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[nmerrill]

Wasn't there info in one of the trans oiling threads about brass fittings that had the correct thread for the Trans bungs?

I.E. something to use other than the stock bungs? Can't seem to find a source...

Is that m22?

[ALIKA T3]

[flomulgator]

I specifically left out the 4th gear splash plate because I assumed it was going to interfere with direct oiling via the fill port. If the choice was between oiling via splash plate or via circulation there is no contest as to which is better. If you were shooting oil straight in (as was my original plan) the danger is that the oil could all just shoot downward off the plate instead of upwards, to the detriment of 4th gear and the mainshaft bearing. If you could get both with a nozzle like this then it would be a win-win.
_________________
She's built like a steakhouse, but she handles like a bistro!

[Sodo]

If anybody wants to bring me an SA splash plate I'd like to bolt it onto my housing and verify a nozzle can get by it. Also would like to extend the nozzle a little. I think there are a lot of splash plates already installed by the big-engine crowd because it was the best option available.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[ejimmi]

Sodo have you pumped oil through the fittings to see how/where it flows? Pinching the tip of the outlet to guide the oil between the gear and case (in to the bearing) may be of benefit, as you don't want to shoot oil into the gear-mesh.

Looks like you are shooting the oil in the exact spot herman did in this thread, and he has had pretty good success even with a mag carrier. Edit: although he was squirting the bearing from both sides.

http://www.thesamba.com/vw/forum/viewtopic.php?t=621285

On another note, Sodo, have a look at his like new 9 year old drilled pinion bearing. Unfortunately i don't know if it is 30K/mikes or 30K/KM.

[Sodo]

Great stuff. I may have seen that, but forgot about it because it was early in my research, and due to the volume of info to digest. Thanks for the link and the reminder! Here's Herman's pic next to my bung nozzle.

One thing I like most of all is the 30,000 mile report! I am becoming highly motivated to drill & oil my pinion bearing.

This bung-nozzle project is simply a hobby-endeavor to help out the folks who want to add a cooling system to a "running" transaxle.
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[ejimmi]

If you do run the oil test with the tube squirters, you may also want to retest the plate oiler you made in your housing with gear oil. I know you already tested with water but the gear oil will obviously flow differently.