How to know it’s time time for a tranny rebuild?

[MarkWard]

The 091 4 speed is about an inch and a half shorter than the 091/1 4 speed. Don’t have the measurement you seek, but wanted to point that out since the packed one above is from description an 091 4 speed.

[steve244]

Correct. The box had a couple inches to spare, but it'll be snug.
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82 AC vanagon approx 200K miles (3K are mine).
DD is a 2015 Leaf
Road Trip to Hell (FL 2023)
The Vanagon's drivetrain and chassis restomod thread. Best sung to the tune of I Did It My Way...

[steve244]

I gave the wrong length of the plastic box above.

It's 26 to 27 inches long inside. The earlier type 91 fit with a inch to spare.
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82 AC vanagon approx 200K miles (3K are mine).
DD is a 2015 Leaf
Road Trip to Hell (FL 2023)
The Vanagon's drivetrain and chassis restomod thread. Best sung to the tune of I Did It My Way...

[WillRB]

Have everything removed including the starter bolt but struggling to get transmission to release from engine studs. Have an adapter plate (2.2 Subuaru). Any tips? I have removed motor but never transaxle. Would some gentle prying between adapter plate and transmission case be out of line?
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1984 Vanagon Westfalia w/ Subaru Conversion (99 Legacy 2.2 Phase II) 2WD 4speed 4.57 R/P (.828 straight cut 4th) GT TBD

[MarkWard]

Gentle pressure would be ok I believe. There is likely a register on the adapter plate for the bell housing, dowels, or something to index it square that could be sticking.

[WillRB]

I don’t need to loosen the engine carrier (RMW) at all do I?
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1984 Vanagon Westfalia w/ Subaru Conversion (99 Legacy 2.2 Phase II) 2WD 4speed 4.57 R/P (.828 straight cut 4th) GT TBD

[MarkWard]

I do not know the answer to that question. Do you recall if the adapter plate was attached to the engine case and then the flywheel installed? For the adapter plate to unbolt from the engine, it would need to be able to pass over the flywheel. That would not leave much meat for the adapter. Might want to start another thread to get better response.

edit, mis read your last post. I don't see a problem loosening the engine carrier if it gives you more droop on the transmission end. You need to be able to clear the chassis with the nose of the transmission. I usually remove the complete transmission bracket to gain more room.

[WillRB]

[WillRB]

Well a bit of an update. Not ideal news on my transaxle teardown at builder. Ring and pinion damaged. Potentially a couple other issues. Turns out someone had “hodgepodged” together the transaxle at some point. 4.83 r&p, 2 spider gear diff, with aluminum case. All on my 84 westy. I guess its good that it was discovered as part of a rebuild not after a breakdown across the country..

Might be needing to locate another core. Leads welcome..

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1984 Vanagon Westfalia w/ Subaru Conversion (99 Legacy 2.2 Phase II) 2WD 4speed 4.57 R/P (.828 straight cut 4th) GT TBD

[Sodo]

Bummer about the R&P.
Thass why I say keep clean oil in it.
Theres no economy in running contaminated gear oil longer when clean oil is only $30.

Especially in an old trans that may have an old gear or 2 ready to start shedding steel into the oil at any time.

Well at least you have an Aluminum case!!
Those are hard to find.
Big engine fellers be envious.

Good thing you didn’t “exchange” it away.

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I just saw a video where an aussie guy used a compressed air nozzle to force oil out of a soda bottle, up a tube into a gearbox.
It looked like a great DIY trick.
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[WillRB]

[E1]

I’d personally trust any core that Arizona Transaxle or Mr. Gas had approved for rebuild. They worked long and hard to build reputations that wouldn’t be worth risking for a few hundred bucks.

I can’t comment on other builders, but myself would in general trust their judgment over buying a completely-unknown core, especially from a private party without personal knowledge of them.

Builders not only know what they’re looking at that a private party isn’t likely to, but the last thing a builder would need is rebuilding on a bad core just to have it come back for warranty.
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If ever twice as rich, we’re gettin’ a double-wide
’84 “Westfailure”/2.1 Digijet/5.43 Ring & Pinion/Peloquin/D-rated BFG KO2s

AI has spoken to further illiteracy, to steal, to cheat, and to replace humans

[zerotofifty]

Here is a nice little video on tranny synchronizers you all may enjoy.. Even has strobe light action video!

https://m.youtube.com/watch?v=e-Lk3FXHubw
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Sorry About That Chief.

Give Peace a Chance.

Words to live by.

[E1]

Great video, Thanks!
_________________
If ever twice as rich, we’re gettin’ a double-wide
’84 “Westfailure”/2.1 Digijet/5.43 Ring & Pinion/Peloquin/D-rated BFG KO2s

AI has spoken to further illiteracy, to steal, to cheat, and to replace humans