Automatic to Manual conversion?

[reluctantartist]

I have the opportunity to get a manual transmission setup from a fellow samba member and I do like the idea of having a manual instead of an automatic, but from what I have read the automatic is going to be easier to keep going do to parts availability verses the rarity of the manual tranny. I would have all the parts except for the clutch and flywheel. Are flywheels for 412's the same as a bay/vanagon? Are these parts easy enough to get if 412 specific. Will the MPG be that much different? I really can't afford to sink a lot more time into modding and getting parts so if this is not a straight forward swap I will stay with the auto tranny.

Thanks all.
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1982 Westy, 1974 412 Variant... Yes, Aircooled's are great! Oh and I do have modern computer controlled vehicles too, but I just don't care about them.

[raygreenwood]

The standard tranny will run for a zillion miles as long as it has not been driven too far with one of several common problems typical of 004 four speeds.

I have written extensively of everything needed to work with these mostly on the STF...but some here too.

The first thing you need to do...absolutely do...no matter how good the tranny seems....is to strip it down. No special tools required until the differential and I can walk you through that when you get there. You need to replace the counter shaft bearings and countershaft...always. When they start to wear...it will destroy the transmission if it gets too far. these two 20mm needle bearings had poor oiling.
That is a simple fix....and...you should switch from needle bearings to glass filled torlon bushings....about $60 to have machined...and put a new shaft in. This is just a straight 18mm shaft cut to length with a 15mm notch ground on the end....about $80 total. If your shaft is still good...just the torlon bushings, some widening of the existing oil hole and some filed and polished slots at each end of the counter gear cluster will suffice.

You should replace the differential and pinion bearings and seals. I can walk you through this. Its not hard....just tedious. Also replace and check the differntial spyder gears. Poor adjustment at the outer shaft ends will spall the teeth on these and these will destroy the differntial when they.

I have fixes for all of these things. I have fix I am going to try this summer for slightly worn synchros but generally that is not an issue.

Before switching over....get the transmission and the spend the time. The Haynes manual is pretty good for teardown. I will be happy to wlak you through the points.

Installing in the car is a breeze. You need the hydraulic cylinder....and either entire pedal cluster or the parts to attch to yours. Make sure your clutch master has the residual pressure valve in place. get the clutch tubing or be prepared to bend some. You will need a flexibleng to fit the slave and clutch hose from a vanagon. Contact me for part #. beyond that youwill need about 5 feet of yubing with one flared fitting to fit the slave and a female high pressure union (mcmaster carr has these) to connect to the flexible hose.

All of the holes and hold downs for the cylinder hoses and tubes are already in the body. So is the forward shift rod bushing mount point. You will need the shift rod, shifter, shift gate...and very importantly....the plastic shift rod guide plug that closes off the tunnel in the rear. The holds the shift rod at the right height. You also need the two piece floatong shift coupler.

I also have a fix for that floating coupler and for proer shifter adjustment that is not in the books. It fixes a shifter coupling flaw from the factory.

If you have all of the parts....this is about a 4-6 hour total job for install. Ray

Short of worn synchros which is rare

[Wildthings]

I have both an 004 and a side shift 091 tranny that I am considering installing in my 411. The 004 would be a easier install by far, but the 091 is a very stout box and should last until we have mined the last of the oil shales.

[raygreenwood]

The 091 will be an interesting install. How you deal with the tailcone configurationwill be interesting. The 091 is (I think) a bit heavier...and does not have the high final drive you really want in the 411/412. The final drive in the 004 box was perfect for the car and the torque band of the high compression 1.7L . Ray

[Wildthings]

[raygreenwood]

Ah!...forgot about the nose cone difference. Set it up with a vanagon style clutch slave working the clutch lever and it should do well. Yes...the ratios should be ok....just not quite as quick as the 004.....but parts are more available. Ray