TheSamba.com :: View topic - Building a better Vanagon automatic transaxle

Tue Aug 09, 2022 9:11 am

Thank you for the response skills! I will do as you say and follow up.

Thu Nov 03, 2022 4:14 pm

Pro tip for folks who want to ship a Vanagon automatic transaxle.

Separate the differential from the transmission. The diff can then be shipped in the Igloo Sportsman Latitude 60qt rolling cooler.

I had to use a Dremel to cut back the underside of the lid a little bit, but once that was done, the differential fit nicely, and the voids were stuffed with bubble wrap. I then used a webbing strap to strap the lid down, duct taped it securely, and dropped it off at UPS. The 102 lb package with $500 declared value was about $200 to ship.

kourt

Thu Nov 03, 2022 4:48 pm

that ships just the Diff?

but what about the AT portion?

Fri Nov 04, 2022 6:39 am

The AT is smaller and an easier problem to solve. Smaller cooler, etc.

The challenge is shipping the oddly shaped and heavy diff, which is why I bothered to post about it.

kourt

Fri Nov 04, 2022 7:38 am

ok so you're shipping an Automatic in 2 parts in 2 separate coolers

how does a rebuilder shop return a rebuilt one?

Fri Nov 04, 2022 8:43 am

I'm pretty sure they palletize a complete transaxle for shipping. But palletizing is itself expensive, and then it costs more to ship palletized things. With this cooler idea, I was able to go to the sporting goods store and buy the right cooler, and take the whole package to UPS.

kourt

Sun Sep 17, 2023 10:06 am

Hi Everyone

Really great thread this, thanks to all contributors, its been a great read

My 88 Vanagon has the 010 autobox and i got it 2.5 years back, its always been funny about engaging reverse but last year i had to rev it to get it to engage. Didnt drive the van from last autumn until April this year and felt it was time for an engine change so planned and got stuck into that, link here:

https://club8090.co.uk/forum/viewtopic.php?t=178862

Unfortunately as i got home the autobox refused reverse so had to be pushed into place, shame really as it was an incredible drive even as it skipped down from top gear and wouldnt go above 2.

Now i have to rebuild the 'box and am thinking to just do a stock rebuild, order the parts that Kourt bought from Wittrans and follow the various great guides here.

My only issue is i am in the UK so a delayed delivery time and im thinking i will just order everything and build from there although i havent pulled the autobox yet, 1 and 2 are still functioning so having read the Bentley manual the fault is seperate on D and R. thinking this is a safe way to go to get me moving.

I build aircooled engines so have a good mechanical knowledge but this will be a first for me. When i was starting the engine conversion i had a gearbox specialist lined up to assess and sort the 'box but they refused it when i turned up! So it has to be me and that isnt a bad thing i dont think.

Any advice welcome if i should strip it down before ordering parts but with an unknown mileage/history i think it best just to go all in as i wont know one worn steel from another.

Any first step ideas welome thanks

Wed Dec 27, 2023 1:38 pm

Does anyone know the size of the o-ring on the differential adjusters? The part number is 011-519-345.

I can't find it on any of the typical Vanagon suppliers or any other reputable site. Figured I could just order them from the o-ring store or something but wasn't sure the size.

Wed Dec 27, 2023 2:10 pm

Send me a PM and I'll send you a link to a place to order them.

Mark

blackglasspirate wrote: Does anyone know the size of the o-ring on the differential adjusters? The part number is 011-519-345.

I can't find it on any of the typical Vanagon suppliers or any other reputable site. Figured I could just order them from the o-ring store or something but wasn't sure the size.

Wed Dec 27, 2023 2:35 pm

I'm only assuming that the differential sub kit has what you need, I haven't ordered one myself.

Mark

Wed Dec 27, 2023 3:34 pm

In a pinch, you can buy a larger O ring and cut it to size. Make sure your cuts are square and super glue the ends together. Might want to practice your technique first.

Edit: if you can determine the dimensions check McMaster Carr.

Thu Sep 12, 2024 11:50 pm

Quote:

The two holes on the left of the picture and the far right hole are pressurized to engage the metal clad seals in the clutch packs.

You have first/reverse and that clutch pack can be seen up inside the transmission and energized with compressed air in the far left hole. Use a rubber tipped nozzle and some air pressure and look..you will see the drum push the clutch pack. There is a pronounced "clunk" too.

Now using compressed air pressurize the other hole next to the far left hole..you can't see this clutch pack..but should hear a solid "clunk"..that is your forward clutch pack..which is most likely not working..you may hear air escaping and no "clunk" ..the forward clutch pack is engaged all the time and when it fails you lose 2-3 gears.

Now go to the far right hole..and pressurize it..you will probably hear a "clunk"..that is your direct clutch pack..that is your 3rd gear.

The middle hole goes to the pump..no testing with air pressure there.

Hello, I have a Gearbox WITHOUT the oil cooler ports and i would like to add it.
I've found some photos in previous posts but there is some contraddiction.
In reference of this photo:

In this photo (original ports for cooler) the output port seems to be on the yellow little circle hole

In this other photo of a gearbox without ports that is been drilled from someone to add the ports, seems to be on the green square hole.

Where I have to drill? The green square or the yellox circle? wich dimension? The oil I "steal" from this hole (and I take to the cooler and then back again to the pan) where did it go without my drill? I'm afraid to "steal" oil and falling the pressure down from some component and break something...

Fri Sep 13, 2024 5:43 am

I believe the return from the cooler goes to the middle of the transmission Oil Pump, and is visible to the end of the oil pump shaft when looking through the factory hole from the outside of a Transmission that came with the Cooler Ports.
If I'm wrong about this, Kourt will correct me.... :lol: :lol:
To me, your labeling seems backwards, if, the return port is indeed centered on the case due to the location of the pump inside the Case.
Here's a couple of pictures of the end plate of your Oil Pump. The big hole in the middle of the plate is your return as far as I know. When your trans is assembled, you can see the oil pump driveshaft end through this hole, engaged in a drivepiece aka, the Flower, that turns the pump on stock Cooler Drilled transmissions.
I might have time this weekend to take my spare trans out of its storage box and look over the port locations if Kourt doesn't respond back on this thread.

Fri Sep 13, 2024 8:36 am

For the record:

The 090 Vanagon transmission has two cooler ports:

The top port feeds cooled ATF from the cooler into the transmission and the center of the ATF pump like jlrftype7 suggests.

The bottom port, nearest the ATF oil pan, is where hot ATF exits the transmission for cooling in the ATF cooler.

I know your post wasn't exactly about that, but it's worth noting.

It was hashed out in this thread, which must be carefully and fully read to get the correct answer.

There was a thread somewhere on The Samba about a guy who drilled his Audi/air cooled trans case for fittings, and I thought he used the same locations as the 090 case casting.

Before I gave all my transmissions away, I had an Audi case that had no cooler ports. I really wanted to drill it to see if this would work, but that project got away from me.

kourt

Fri Sep 13, 2024 8:42 am

kourt wrote: For the record:

The 090 Vanagon transmission has two cooler ports:

The top port feeds cooled ATF from the cooler into the transmission and the center of the ATF pump like jlrftype7 suggests.

The bottom port, nearest the ATF oil pan, is where hot ATF exits the transmission for cooling in the ATF cooler.

I know your post wasn't exactly about that, but it's worth noting.

It was hashed out in this thread, which must be carefully and fully read to get the correct answer.

There was a thread somewhere on The Samba about a guy who drilled his Audi/air cooled trans case for fittings, and I thought he used the same locations as the 090 case casting.

Before I gave all my transmissions away, I had an Audi case that had no cooler ports. I really wanted to drill it to see if this would work, but that project got away from me.

kourt Thanks Kourt- I STILL regret not being able to drive down to Texas to get some of those trans parts from you.... :cry: :cry: :cry:

Fri Sep 13, 2024 9:43 am

I have regrets too. I spent considerable time and money to package the two transmissions and one differential in coolers and ship them to someone who was needing parts. It was a charity effort. I didn't ask for any money from him, and he said he was broke and couldn't pay me anything at that time, but made a vague promise about sending me some money sometime. I didn't care about the money.

Never heard back from him--not even a "thank you" or a confirmation that the parts arrived. Crickets.

I don't really subscribe to the idea of Karma, but I do believe good deeds make the world a better place for everyone.

kourt

Sun Sep 15, 2024 10:09 pm

jlrftype7 wrote: I believe the return from the cooler goes to the middle of the transmission Oil Pump, and is visible to the end of the oil pump shaft when looking through the factory hole from the outside of a Transmission that came with the Cooler Ports.
If I'm wrong about this, Kourt will correct me.... :lol: :lol:
To me, your labeling seems backwards, if, the return port is indeed centered on the case due to the location of the pump inside the Case.
Here's a couple of pictures of the end plate of your Oil Pump. The big hole in the middle of the plate is your return as far as I know. When your trans is assembled, you can see the oil pump driveshaft end through this hole, engaged in a drivepiece aka, the Flower, that turns the pump on stock Cooler Drilled transmissions.
I might have time this weekend to take my spare trans out of its storage box and look over the port locations if Kourt doesn't respond back on this thread.

The return port in original VW cooled transmission is in the centre of the oil pump.
But in my opinion, the return can be everywhere in the pan (have to drill in the center of the pump with the transmission assembled is very difficult, I think...). Obviously it's better to give to oil pump the cooled oil, but if you cool ALL the oil of the pan, then the pump take the cooled oil by the pan, so I think it's the same.

The question is about the feed of the cooler. In the original cooled transmission, is the port on the yellow little circle hole or in the square green hole? Anyone who has a original cooled transmission can verifiy?

Thanks

Mon Sep 16, 2024 10:48 am

kourt wrote: I have regrets too. I spent considerable time and money to package the two transmissions and one differential in coolers and ship them to someone who was needing parts. It was a charity effort. I didn't ask for any money from him, and he said he was broke and couldn't pay me anything at that time, but made a vague promise about sending me some money sometime. I didn't care about the money.

Never heard back from him--not even a "thank you" or a confirmation that the parts arrived. Crickets.

I don't really subscribe to the idea of Karma, but I do believe good deeds make the world a better place for everyone.

kourt So sorry to hear that. I've had a couple of Samba experiences like that, one, I sent a good used Plastic Dust Cover for the Top of the Instrument cluster to someone who was promising to make reproduction covers with their very pricy Vacuum Machine. They even sent pictures of their work space and the Machine. I was only out $20 for the Cover from one our West Coast Used Part guys, plus shipping to the Easy Coast, but like you, Crickets once the part got to them.
They've never replied to the 2 PMs I sent them once they received the Stock Dust Cover, regarding what was going on, any progress, etc. :roll: :roll: :roll:
I gave up- it's apparently never going to happen. And we'd actually buy those covers most likely if they ever offered them for sale, since they're NLA.
:( :(

Tue Jul 29, 2025 12:06 pm

kourt wrote: I have regrets too. I spent considerable time and money to package the two transmissions and one differential in coolers and ship them to someone who was needing parts. It was a charity effort. I didn't ask for any money from him, and he said he was broke and couldn't pay me anything at that time, but made a vague promise about sending me some money sometime. I didn't care about the money.

Never heard back from him--not even a "thank you" or a confirmation that the parts arrived. Crickets.

I don't really subscribe to the idea of Karma, but I do believe good deeds make the world a better place for everyone.

kourt

I wanted to followup that the person I sent my last Vanagon auto transaxle to eventually did surface and communicate with me and send me money for the transaxle. That was a nice gesture that deserves recognition. The world is still a good place.

kourt

Tue Jul 29, 2025 2:52 pm

kourt wrote: kourt wrote: I have regrets too. I spent considerable time and money to package the two transmissions and one differential in coolers and ship them to someone who was needing parts. It was a charity effort. I didn't ask for any money from him, and he said he was broke and couldn't pay me anything at that time, but made a vague promise about sending me some money sometime. I didn't care about the money.

Never heard back from him--not even a "thank you" or a confirmation that the parts arrived. Crickets.

I don't really subscribe to the idea of Karma, but I do believe good deeds make the world a better place for everyone.

kourt
I wanted to followup that the person I sent my last Vanagon auto transaxle to eventually did surface and communicate with me and send me money for the transaxle. That was a nice gesture that deserves recognition. The world is still a good place.

kourt
Cool, so glad that's finally worked out and settled for you.