The Berg 5 Speed Thread

[Root_Werks]

Rancho gear and Fulcrums should arrive today. I should get my box off to my builder next week.

I did pull off the nose cone, but that's as far as I'll go. I'm not a Engine or Tranny builder.

Here's a couple of pics (fuzzy, sorry) of the .82 screaming 5th. Screams under load, quiet no load. Until the gears are removed, not sure there's anything to be seen. I can see shinny areas where the gears mesh.

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When I set my timing, why do I flush, then take a pee?

[Root_Werks]

The other issue I'm running into is hearing/feeling the axles/fulcrums after driving anything over 70mph for 15+ minutes. It's like there isn't enough oil getting to them?

Yes, the trans oil was filled properly.

Right side never made noise, Left side did. Last freeway drive I pulled off and was freaked out a little when I could hear the left side making noise. Quieted right down once off the freeway. Way home, kept under 65mph and it was fine/quiet.

Check out the fulcrums though, yikes. Right side had a .005" gap between axle and fulcrum. Left was .010", maybe too much gap?

Super Diff has oil mod holes.

Thoughts anyone? Going to put all this back together and would love to drive 75+ mph.

-Dan

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When I set my timing, why do I flush, then take a pee?

[Bruce]

Your side covers need to be modified to allow oil to go around the diff to the axle side. Good thing you posted those pics while you have it apart so you can fix the side covers.
Every trans with a superdiff needs this modification done.

Here's what VW did for cars that had a limited slip diff:

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[gears]

Those side cover mods shown by Bruce are necessary for swingaxle LSDs and TBDs, as well. Regarding the SD body itself, I'd go the extra mile as shown by Ray Vallero (RIP). https://www.thesamba.com/vw/forum/viewtopic.php?t=622360
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aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

[Root_Werks]

Wow, thanks guys! I'll pull the side covers off and check for the mod. I have a scope camera, but don't think I could bend it up enough to see if the mod has been done or not. My builder did the oil holes on the SD I know for sure, but don't know if anyone modified the side covers.

-Dan
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When I set my timing, why do I flush, then take a pee?

[Bruce]

The modifications are visible from the outside. Since you already have the axle tubes off, you should be able to see.
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[Root_Werks]

Popped a cover off just to be certain. No mod. Sure explains things.

Well, feel like I've got a plan at least.

Not 5spd specific, but figure anyone building a Berg5 swing will probably lave either a SD or LSD.
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When I set my timing, why do I flush, then take a pee?

[Root_Werks]

Don't want to turn this into a build thread, but thought this is a good picture of 5th gear removed and nose cone off.

New GT .82 going on in place of the unknown (no markings) .82 gear set that really screamed under load. Since everything checked out, we're hoping/assuming it was a miss-matched set.

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When I set my timing, why do I flush, then take a pee?

[Brent]

Here's one that can go totally sideways...

What oil are you using in yours?

I'm planning on Swepco 201.
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69 Fastback Build
Berg5 Build

[Root_Werks]

[Root_Werks]

Since I pulled the Berg5 out again, wanted to show another minor mod I had to make to the mid mount.

Berg5's require the mid-mount be used. I'm on a 1966 frame so this mod may/may not apply to other year frames. The mid mount didn't touch, but it was very close to the Right frame horn. I didn't notice until after everything was installed and used a sawsall to cut a small notch out. Hard contact of drivetrain to frame or body transfers a lot of noise and this was a definite possible contact point.

Picture shows I cleaned up the cut a little and were it was cut. The mid mount metal is so thick, seriously doubt this compromises any structural function of the mount:

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When I set my timing, why do I flush, then take a pee?

[Olli from NJ]

I bought Penngrade 1 GL-4. for my Berg5 . Trans builder gave his approval.

https://penngrade1.com/products/gear-lubricants/penngrade-1-classic-gl-4-gear-oil-sae-80w-90/

Olli

[Brent]

[Bruce]

You're right Brent. If you remove the mid mount, you've got a big leak that you'll never be able to seal. That's why I require the mid mount when I do the initial build. Then it's on the trans when it's picked up.

I've never heard of anyone putting nuts on the gear carrier then adding the mid mount. The studs aren't long enough to take an extra nut.
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[Brent]

[Bruce]

[Root_Werks]

I wouldn't install a Berg 5spd without the mid mount. Berg's blue bible states it's a requirement. When I get my Berg5 back, I'll snap a pic of the mid mount on the trans.

Fitting the Berg5 to the Bug took some time. The mod's in the blue bible can't be ignored.

-Dan
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When I set my timing, why do I flush, then take a pee?

[Root_Werks]

Here's a good shot of the mid mount on the trans. Just 4 studs need to be about a 1/4" longer:

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When I set my timing, why do I flush, then take a pee?

[Root_Werks]

"Rancho" hybrid fine tooth .82 installed and much quieter than the generic .82 I was running. You'll be very happy with it.

-Dan
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When I set my timing, why do I flush, then take a pee?

[Failer]

I know from this thread that the B5 conversion lengthens the nosecone a bit and requires some clearancing of the body. Is that the only obstacle to it being a straight bolt-in thing? Does the nose cone keep the mount and the length of the gear selector the same? I mean, do the shift coupler or rod need to be moved or modified as well?