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Tue Aug 27, 2013 8:40 am

.. plus some.

This thread will be something of a continuation of previous threads, with an emphasis on oiling upgrades (primarily to address 4th gear overheating).

http://www.thesamba.com/vw/forum/viewtopic.php?t=534623&highlight=syncro+transaxle+service

While I've had to turn down a few Sambanistas, Zeohsix's 094 project intrigued me because of:
1) Access to a full machine shop
2) Eric's wish to actively participate in machining and parts preparation for his build.

Eric "hit the jackpot" with his late model factory built replacement 094 transaxle having an aluminum main housing:

Because we have time constraints, and I may not be able to add material on a day-to-day basis, I'm putting forth some of the photos now. I probably won't be able to wrap up this thread until after the build is complete, and I'm sipping lemonade on Kailua Beach.

Some of you are familiar with our friend Herman's transaxle modifications .. oil drilled pinion bearing and gun-drilled mainshaft.

While we've followed some of what Herman has done, we've gone a different direction with addressing 4th gear heat build-up. Much more to follow ..

Tue Aug 27, 2013 8:49 am

Cool 8) 8)

Tue Aug 27, 2013 8:52 am

Many of the aluminum South African intermediate housings require finish machining:

4mm holes drilled & tapped:

Half moon for bearing locking plate:

The half moon on this housing was rotated counterclockwise a bit. This exact location can only be used because a bearing plate will be added .. otherwise, the low gear housing would fail to retain the locking plate in this position (should normally be rotated clockwise a tad).

Some SA housings also require that the oil-add hole be drilled & tapped. Thankfully, this one was previously done.

Edit: My oiling hole can be seen on the left. This is why I moved the half moon .. although I really didn't need to move it this much.

Tue Aug 27, 2013 1:00 pm

Welded ..

.. and prepared for oil feed to pinion bearing:

Tue Aug 27, 2013 3:07 pm

Thank you very much for documenting this process.
I am envious. 8)

Tue Aug 27, 2013 4:53 pm

Yes.
Thank you.

Tue Aug 27, 2013 6:32 pm

I planned my SVX conversion back in 2008 (delayed by life until 2012)without any knowledge of the inherent weaknesses in the 094 syncro gearbox. At the time in 2008, I was imagining zooming up mountain passes with a couple ATV's on a trailer behind my Syncro Westy SVX. Then I learnt about the weaknesses of the 094 and have been listening carefully ever since for odd noises (none yet, thanks to Daryl's rebuild and upgrades) and have not yet towed anything, let alone a pair of quads.

I, for one, am overjoyed that the Samba brain trust has found a solution to these 094 weaknesses and that Paul Guard is now posting a pictorial to boot.

Bravo!

Tue Aug 27, 2013 10:40 pm

Nice work! Great thread!

Tue Aug 27, 2013 10:43 pm

very interesting stuff, don't be shy with the pictures :)

Tue Aug 27, 2013 11:17 pm

Paul your showing a photo of the "practice" pinion bearing race. The ones we are going to put into use are much better done! The holes in the practice race look like someone had too many beers and shouldn't be operating machine tools. Pinion race is one of the least fun jobs of the mods other one is finding location of casting webbing to sink a hole into the main case, all the time the drill is going your thinking....did I really get the depth right? I'm going to cry if this bit breaks out the side. It is a pleasure working with you on this project.

Anyone wanting an aluminum case 094 there seem to be some New Old Stock VW trans axels popping up on EBay. Bring a fat wallet! In fact I think a fat wallet is required for anything to do with a Syncro transaxel :P

Wed Aug 28, 2013 6:07 am

Some day when our pinion bearings are obsolete, I'll be digging for that wonky practice race ;>)

.. and yes, I know the feeling of drilling those long "prayer" holes .. kinda like installing your first set of piston squirters in a new engine case.

The bearing rollers just clear the drilled holes:

.. We'll chamfer all drilled holes, just the same:

Wed Aug 28, 2013 6:21 am

As long as we're peering through the microscope, any imperfections in the bearing's threads are located and removed, thus avoiding the possibility of a seized chromoly pinion nut.

Wed Aug 28, 2013 10:23 am

Working on an oil delivery path:

5mm & 6mm mounting holes; Large oblong oiling hole will hopefully deliver oil at a moderate flow rate, without squirting beyond where we need it:

Wed Aug 28, 2013 10:28 am

Daryl's bearing retainer plate with new oiling hole:

Wed Aug 28, 2013 6:54 pm

400HP transaxle isn't that what you promised with lifetime guarantee :D

Looking GREAT!

Wed Aug 28, 2013 7:02 pm

gears wrote: As long as we're peering through the microscope, any imperfections in the bearing's threads are located and removed, thus avoiding the possibility of a seized chromoly pinion nut.

How do you plan to fix this knick?? Weld and recut the thread??

Wed Aug 28, 2013 7:31 pm

Cool thread to watch. Thanks for letting us follow along.

Wed Aug 28, 2013 8:56 pm

gears wrote: .. any imperfections in the bearing's threads are located and removed ..

.. merely means removing high spots with a mini triangular file.

Wed Aug 28, 2013 9:24 pm

Nice, I like how D's plate supports the main bearing all the way around. With the half moon-ish castings pressing against the plate's forward side, it will provide good support, and the added surface area of the plate will prevent those castings from wearing. I considered putting a thin steel shim on those half moon castings to reduce wear but this is so much better. So, I'm guessing you'll skip the gasket on the plate side, or will you still use it and have to shim at the nose casting to account for the added depth? I skipped it per advice (perhaps yours?) and it came out nice and quiet. Will you be using a thin steel shim in the bottom of the main bearing bore?

Whose oil diverters are going in? I about passed out with anxiety drilling those holes in mine.....

DougM

Wed Aug 28, 2013 10:30 pm

The following photos show my arrival at an oil deflector plate design, which will direct cooled oil straight onto the mainshaft ball bearing and 4th gear idler teeth .. the two most overheated parts in the transaxle.

Playing with oil deflector plate shapes:

Final choice of deflector plate .. 5mm bolt on left, 6mm on right

Torquing plate against 11.6mm tall spacer sleeve. Location of this bolt was critical, avoiding the thinest areas of casting.

I like it. Both 4th gear and the mainshaft bearing will receive a generous gush of cooling oil, in the precise area providing the most benefit.

Tomorrow we'll take a look at the neat way in which oil is fed to the front of the intermediate housing.