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Tue Jun 01, 2010 10:22 pm

rossi46 wrote: Around £2800 the bear gearbox I had a spec sheet sent to me last week

I have emailed bear twice thru there website and have yet heard from them or received a spec sheet. can you scan your info and forward me it.
I am in the usa, thanks

Sat Jan 28, 2012 4:01 pm

If I could afford it I'd buy everyone here a Berg 5 this thing is sweet! This post gives a general idea what it takes to get a Berg 5 installed. I'm installing it into a 59' bug or more importantly a 59' floor pan. Rumor is later years will install easier without much modification.

Receive your Berg 5 trans from the builder. Yep that's a breather hose, damn this thing is sweet! wait til' you drive it I'm talking pounding and punching lower gears all around town and cruising home keeping up with traffic listening to your big motor puuuurrrr, you did get a big motor to match up with your Berg 5 correct? just want to make sure we're on the same page if we're looking to have some fun, LOL!!!

Berg 5 mid-mount kit, yes you do need one of these don't cheap out + Berg 5 shifter.

Mid-mount assembled for viewing purposes. Berg part # GB 643F (61' - later), I know it's not for my 59' but it worked. I tried GB 643J (55'-60') but the mid-mount would sit too low causing the weld brackets to not sit fully on the frame horns. Photo comparison of each kit is shown several shots below which will make more sense.

Replace four studs with longer ones (included in above kit) to allow the mid-mount to bolt on. Yes, Berg designed the mid-mount nice and thick so it ain't going nowhere.

Install front mount and do whatever it takes to get the trans aligned (Up and Down) correctly.

May have to notch the corners to fit between frame horns.

If it doesn’t feel right go on your first instincts. Grandparents taught us things we sometimes forget, it's all wisdom.

Below shows the trans sitting WAY TOO high outside of the chassis tunnel damn! Now what do I do? Call Berg? Call Rancho? Do I have the correct mid-mount?? they do have several versions make sure you get the right one Berg was very helpful over the phone and shipping back and forth. The problem here was that if I lowered the trans where I needed it to be, the rubber-bushing studs would not line up to the holes on the front mount, the studs were actually floating in the air. Solution: fabricate a longer (to the ground) front mount, very simple to make.

Chop Chop, remember?? whatever it takes . . . I believe Berg part # B5S PLUG will cover up this hole, I recently noticed this part on their website.

New right side stud (10mm x 1.50) relocated and welded.

Like I said do whatever it takes to get proper alignment even if it means fabing your own front mount, whew that wasn't too bad now on to the next task.

Very Important:
Before moving on install the shiftrod and Berg shifter and shift through all gears making sure it shifts smoothly, you need to push the button to get to 5th, did I say 5th? that is not a typo, LOL!

Below - Comparing two different Berg mount kits to give you an idea of the differences to help your setup.
Left photo - GB 643F (61' - later) has a tighter fit on my 59' but worked out. Right photo - GB 643J (55' - 60') has a looser fit on my 59' and would not allow the brackets to be fully welded the reason I went with the F kit.

Align and weld brackets. Make sure trans is pushed fully forward and bolts tightened to get correct alignment. Keep your mid-mount at least 1/4" or more away from the frame horns you don't want that thing banging around.

Tack weld couple spots helps before welding full beads. This alignment was acceptable keeping everything nice and tight. Again, shift through all gears feeling for smooth shifts before committing to welding.

Cut under back seat for clearance, a dremel tool does the job well if you don't mind going through several cutting discs.

Install your heavy duty race axles, you did get a set right?

You know the rest, hope this was helpful.

Sun Jan 29, 2012 8:14 pm

Do they still make parts for these?

How much pounding/HP will tis modification take?

Can the 5 spd. mod be done on a bus tranny?

Sun Jan 29, 2012 10:11 pm

Yes the type 1 box is available. identical to the one in the recent post. I have the earlier design which doesn't have the new intermediate housing.
They have a bus version available also.

Tue Jan 31, 2012 12:52 am

The B5 can take just as much hp as any 4 speed with like parts. The biggest difference is if you blow it up, the B5 gets REALLY expensive to fix.

The current Type 1 Berg 5 can be installed in a pre-67 Type 2. With or without reduction boxes.

Sat Oct 13, 2012 3:22 pm

I'm finding the breather on my Berg5 is spewing oil.

What have others done to get around this and any pics floating around of where they have ended up sending the breather lines?

thanx

Sat Oct 13, 2012 6:25 pm

There's a number of updated to the Berg 5. One includes adding a 2nd breather above the differential. Last winter I had my redone by Gary Berg. It's been dry ever since.

More pictures: http://www.glenn-ring.com/berg5/

Article in Hot VW: http://glenn-ring.com/resto/Berg%205%20Update.pdf

Sat Oct 13, 2012 6:37 pm

Hate to be a Downer because your doing such great work, But your axle boots are installed wrong. The seams should be on the drivers side at 2 o'clock and the passenger side at 10 o'clock. There's to much stress on the seams the way it's installed. Some rubber cracking, gonna be going down. Keep the updates coming.

Sun Oct 14, 2012 12:36 pm

Yeah Glenn........mine only has the diff vent

I have pics of mine being put together, should i post them up?

Sun Oct 14, 2012 12:45 pm

Glenn wrote: There's a number of updated to the Berg 5. One includes adding a 2nd breather above the differential. Last winter I had my redone by Gary Berg. It's been dry ever since.

More pictures: http://www.glenn-ring.com/berg5/

Article in Hot VW: http://glenn-ring.com/resto/Berg%205%20Update.pdf
I been running the older design with just one breather up front and have had no issues. I am updating to a newer design as shown in Glenn's pic, do you need both or a larger vent up would do?

Mon Nov 25, 2013 8:36 pm

I am looking in to this swap... But i have to buy a little at a time....... Could u put me a lisr together what i need to buy for my 66 beetle also what all is involved thanks

Mon Nov 25, 2013 8:40 pm

Save up and have a pro do it.

If you've never rebuilt a VW tranny it will cost more to have a pro fix your mistakes.

#1 decide on what gear ratios you want.
#2 buy the Berg 5 speed kit
#3 buy the front tranny mount
#4 decide if you'll buy a Berg 5 speed shifter or try to modify a different one
#5 buy all the gears and heady duty parts you want to ad.
#6 get a decent 4 speed core
#7 send everything to a pro tranny shop

Mon Nov 25, 2013 8:46 pm

I have a guy that does vw trans all the time really good ... I have done a few trans with help and not sure on the gear ratio i know i dont wanna be running hot...on long trips. Does it require and machine work

Mon Nov 25, 2013 8:49 pm

The kit includes a new intermediate housing and nosecone.

It does require some specialty tools for the pinion nut and some other fasteners.

Honestly I don't think the actual labor is that much, but the parts are.

Mon Nov 25, 2013 8:52 pm

So exactly how much are the kits... Alone i only plan on runnin a 1776 but this is my dd

Mon Nov 25, 2013 8:59 pm

The basic kit is $1647.67
Front cross member $245.54
5 speed Shifter $275.53

This is the basic kit, minus the 2 gear sets.

Mon Nov 25, 2013 9:43 pm

AXAM wrote: ..., do you need both or a larger vent up would do?
Transmissions never need a large vent. The amount of air that travels through a vent amounts to what you blow in one breath over the time it takes to warm the internals.
The original vent location on the B5 is near the front on their aluminum gear carrier like where Glen's is on the right. Today, the instructions say not to use this location since it did cause some pumping losses when driven many hours at freeway speeds. The new location is above the diff where things turn slower, so there's less pumping.
Berg supplies ¼npt fittings for the vent. This is dumb. A large vent just makes it easier for the oil to get out. I throw the Berg fittings away and install a steel 1/8"NPT fitting that I have welded shut then drilled a 2-3mm hole. All you need to look at is the stock vent hole. It is a small passage that restricts the flow of oil, but still allows air to pass.

Mon Nov 25, 2013 9:52 pm

What do u mean minus the 2 gear sets...

Tue Nov 26, 2013 7:12 am

billy270 wrote: What do u mean minus the 2 gear sets...
Meaning the 2 gear sets in the upper right are not part of the kit. You have to buy them at additional cost.

Tue Nov 26, 2013 8:30 am

What would be a good ideal on final cost ....