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marco_lh
Samba Member
Joined: December 28, 2011
Posts: 20
Location: Montreal, Qc, Canada
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 Posted: Sun Nov 17, 2024 6:27 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| jimf909 wrote: |
Wow! That's impressive.
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This is where the challenge began !
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I figured the challenge began a few years earlier, like where you were trying to build the adapter to achieve .003 tolerance. 
Superb. |
What would you recommend as for the alignment tolerance?
I couldn't find any handbook literature on the alignment requirement, only discussions on forums, so I referred what seemed logical. It was also in-line with what I learned at school regarding motor coupling adjustment.
It was actually pretty easy to achieve. I attached the transaxle with an engine block, no clutch or flywheel. The assembly was put vertically not to influence the dial gauge reading. I then attached the dial gauge on the input shaft and adjust the relative position of the adapter layers until I reached the desired alignment. The adapter was designed with a series of screws to clamp the layers together.
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jimf909
Samba Member
Joined: April 03, 2014
Posts: 7915
Location: WA/ID
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| Posted: Sun Nov 17, 2024 7:50 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| What would you recommend as for the alignment tolerance? |
I don't have a recommendation because what you did is well beyond my practical experience. The point I was trying to make is that I would have found that task alone to be quite a challenge yet you cleared the hurdle relatively easily. Also, when I read that you needed to align the parts to achieve a max .003 tolerance my brain started going through exactly where the play would be (I assume it's the play in the mating splines) and what would be the detriment of not being w/in your defined spec (load on the bearings?) which led me to possibly understanding the nature of the challenge at this stage which sounded challenging to me.
Thanks again for posting. You gave me some things to mull over when contemplating how quality is achieved.
_________________
- Jim
| Abscate wrote: |
Do not get killed, do not kill others.
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Current: 1990 Westy Camper - Bostig RG4, 2wd, manual trans w/Peloquin, NAHT high-top, 280 ah LFP battery, 160 watts solar, Flash Silver, seam rust, bondo, etc., etc.
Past: 1985 Westy Camper - 1.9 wbx, 2wd, manual trans, Merian Brown, (sold after 17 years to Northwesty who converted it to a Syncro). |
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DanHoug
Samba Member
Joined: December 05, 2016
Posts: 5350
Location: Bemidji, MN
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| Posted: Sun Nov 17, 2024 8:53 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| jimf909 wrote: |
| Thanks again for posting. You gave me some things to mull over when contemplating how quality is achieved. |
the Ghost of Phaedrus walks alongside many in this forum....
_________________
-dan
60% of what you find on the internet is wrong, including this post.
'87 Westy & '89 Westy both 2.1 4spd
Past projects can be found at--
www.thefixitworkshop.com |
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inhabor
Samba Member
Joined: September 09, 2012
Posts: 195
Location: florida
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| Posted: Sun Nov 17, 2024 4:28 pm Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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ml
Great project. I had the same problem with my adapters the first time I drove the bus. There was grease everywhere. I solved the problem with a little bit of great stuff. |
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marco_lh
Samba Member
Joined: December 28, 2011
Posts: 20
Location: Montreal, Qc, Canada
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| Posted: Mon Nov 18, 2024 5:46 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| inhabor wrote: |
Great project. I had the same problem with my adapters the first time I drove the bus. There was grease everywhere. I solved the problem with a little bit of great stuff. |
Yeah I had to add some Gasket maker too, but it was not enough let alone without the added plastic protector. I guess you have really great stuff  !
If I was to provide complete kits to customers, even with my new design I'd die-cut some thin star shaped gasket that also covers the head of the m10 screws to avoid grease spillage....
Or supply T4 CV joint just as @Alika suggests!
By the way, thank you Alika for your comments. Did you actually buy or test the T4 CV joint on a T3 shaft?
His alternative would tremendously simplify the spacer and would prevent any of this ! |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 6863
Location: Honolulu,Hawaii and France
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| Posted: Mon Nov 18, 2024 8:35 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| marco_lh wrote: |
| inhabor wrote: |
Great project. I had the same problem with my adapters the first time I drove the bus. There was grease everywhere. I solved the problem with a little bit of great stuff. |
Yeah I had to add some Gasket maker too, but it was not enough let alone without the added plastic protector. I guess you have really great stuff !
If I was to provide complete kits to customers, even with my new design I'd die-cut some thin star shaped gasket that also covers the head of the m10 screws to avoid grease spillage....
Or supply T4 CV joint just as @Alika suggests!
By the way, thank you Alika for your comments. Did you actually buy or test the T4 CV joint on a T3 shaft?
His alternative would tremendously simplify the spacer and would prevent any of this ! |
Hello!
of course, I did it back in 2009. Can't find GKN cv's anymore though, only cheap brands like Meyle.
_________________
Silicone Steering Boots and 930 Cv boots for sale in the classifieds.
Syncro transmission upgrade parts in the Classifieds.
Subaru EJ22+UN1 5 speed transmission
http://www.thesamba.com/vw/forum/viewtopic.php?t=416343
Syncro http://www.thesamba.com/vw/forum/viewtopic.php?t=4...num+gadget |
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uberaudi
Samba Member
Joined: June 24, 2013
Posts: 529
Location: Hi-top Country
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| Posted: Mon Nov 18, 2024 12:12 pm Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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This is a great thread...thanks for documenting all you have done. With 996 transaxles being sub 1k, this is a very viable option to consider for those looking to rebuild their stock trans. I know I am!
_________________
'84 Adventurewagen 1Z Tdi, '86 Syncro tintop WBX...for now |
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GreggK
Samba Member
Joined: May 17, 2008
Posts: 981
Location: Colorado/Philidelphia
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tdivan82 
Samba Member
Joined: September 17, 2023
Posts: 220
Location: Virginia
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| Posted: Tue Nov 19, 2024 8:34 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| Wellington wrote: |
Amazing.
My first thoughts were the TDI would not develop the HP required for the 996 transmission, |
For a transmission, it's torque that matters. A tuned 1.9 liter TDI can actually put out MORE torque than a stock Porsche 996.
| marco_lh wrote: |
| I'll be adding a ground strap directly from the starter. It's a good idea. I can't believe I did not think of it before! |
I just did this job myself, some photos near the bottom of page 1 in this thread.
_________________
- George
'82 Westy TDI |
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vanis13
Samba Member
Joined: August 15, 2010
Posts: 4031
Location: ABQ NM USA.... Except when not
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| Posted: Tue Nov 19, 2024 8:43 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| tdivan82 wrote: |
| Wellington wrote: |
Amazing.
My first thoughts were the TDI would not develop the HP required for the 996 transmission, |
For a transmission, it's torque that matters. A tuned 1.9 liter TDI can actually put out MORE torque than a stock Porsche 996.
| marco_lh wrote: |
| I'll be adding a ground strap directly from the starter. It's a good idea. I can't believe I did not think of it before! |
I just did this job myself, some photos near the bottom of page 1 in this thread. |
to link to a SPECIFIC post in a discussion, click on the "page" icon right in front of the word "Posted" in the post header. It will open up as a link to that specific post in the discussion. Then you can copy/paste that address to link to -
https://www.thesamba.com/vw/forum/viewtopic.php?p=10304753#10304753
_________________
83.5 Westy with Subaru 2.5, 4 spd manual, center seat, COLD A/C on 134a!, Winter camp heated with an Espar B4 gasoline furnace
www.SuperVanagon.com - some stuff I make |
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tdivan82
Samba Member
Joined: September 17, 2023
Posts: 220
Location: Virginia
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| Posted: Tue Nov 19, 2024 9:02 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| vanis13 wrote: |
| to link to a SPECIFIC post in a discussion, click on the "page" icon right in front of the word "Posted" in the post header. |
A ha, I was looking for how to do that but missed the tiny little icon! Thank you.
_________________
- George
'82 Westy TDI |
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WillDahThrill
Samba Member
Joined: January 09, 2014
Posts: 21
Location: Pasadena, CA
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| Posted: Wed Dec 11, 2024 12:14 pm Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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Amazing job! And I'm so happy to stumble across this thread.
Glad to hear that you are open to making this an open source project. I wonder if you have thought any further about how to document this to make the process a little easier for folks like me trying to decide on tackling a project like this. I would love a step by step kit with instructions, but of course that's going to be out of reach at least at this point in the project.
I think to start, a parts list is needed and should include alternatives with pros and cons if possible. Some people will have different engines, different mounting angles, different junk yard parts available, etc...
I'm sure you did a ton of research and it would be good to get some more of your conclusions documented in the thread. Do you have a list of transmission codes for example?
Someone else mentioned these are sub-$1000 transmissions...wondering how to source one since what I see on marketplace right now for $2k is on that needs a rebuild already.
For example, I have an ALH mTDI mounted upright (not slanted over at 50 degrees or whatever it is). It would be good to have an additional adapter drawing for that. I'm also in a '72 so not the Vanagon...please don't kick me out because of that 
For Axles, you made spacers in order to reuse existing axles. Are there other/better options if buying new?
For shifters, i like that you have CAD designs you've shared! I've also read that the boxster shift cables can work? Ultimate Engineering is also an option i believe.
I'm coming from an 010 Auto trans so I'll need a full clutch setup too. What is the right flywheel. I think I need to get the original bus clutch pedal and linkage...wondering what else though.
Looking forward to seeing this develop further as a project and hope to contribute some day by doing the conversion myself! |
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skills@eurocarsplus
Samba Peckerhead
Joined: January 01, 2007
Posts: 17513
Location: sticksville, ct.
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| Posted: Wed Dec 11, 2024 1:40 pm Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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| WillDahThrill wrote: |
Someone else mentioned these are sub-$1000 transmissions...wondering how to source one since what I see on marketplace right now for $2k is on that needs a rebuild already.
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These are big $$ transmissions. I have a 911 that I'm working with now and the trans is 10k for a basic rebuild and a 5k core
and same thing, a 3k 911 trans is a core what doesn't have a hole thru the side of it
I mean, what's being proposed here is in the realm of syncro $$
_________________
| gprudenciop wrote: |
my reason for switching to subaru is my german car was turning chinese so i said fuck it and went japanese....... |
| Jake Raby wrote: |
| Thanks for the correction. I used to be a nice guy, then I ruined it by exposing myself to the public. |
| Brian wrote: |
| Also the fact that people are agreeing with Skills, it's a turn of events for samba history |
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marco_lh
Samba Member
Joined: December 28, 2011
Posts: 20
Location: Montreal, Qc, Canada
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| Posted: Thu Dec 12, 2024 6:38 am Post subject: Re: G96.31 transaxle adapter kit to TDI @ 50º - OPEN SOURCE PROJECT |
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Back in 2018 when I bought mine, they were selling around 1500$ CAD.
I just checked this morning and there are a couple options for Non rebuilt transaxles under 65K miles between 2K ~ 2.5K$ USD. This is for the Non turbo 996 version. |
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WillDahThrill
Samba Member
Joined: January 09, 2014
Posts: 21
Location: Pasadena, CA
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