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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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 Posted: Sat Sep 05, 2015 12:40 am Post subject: |
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Today I worked on the mainshaft ball bearing oil squirter.
I received the WSV8L fitting I ordered from UK, same as this one here: http://www.kramp.com/shop-gb/en/411048/494720/260587/WSV8L+Bulkhead+elbow+8L
I saved an oil feed line for a 1.8 Turbo engine from an Audi A4 I found at the junkyard. All stainless steel, has 8mm hard tubing with nice bends,a banjo on one end, a flex line 8L on the other end. Lots of things to hack out of it 
Brazed in one end of the fitting. I had to modify the angle to slide the nut onto the threads and bend it back in when assembling on the low gear housing.
A little misalignement....
All good now, easy to check with an old bearing carrier and an old bearing in place 
_________________
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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Waldi
Samba Member
Joined: February 28, 2014
Posts: 1752
Location: Germany
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| Posted: Sat Sep 05, 2015 4:16 am Post subject: |
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| I see problems pressing oil into the G-Gear case, and revoming it from main case. |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Sat Sep 05, 2015 11:53 am Post subject: |
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I'm not a physicist, but I have some decent logic thinking.
If the supply and return have the same flow rates and the added oil circuit has been taken in account for extra amount of oil needed, I'm not "removing" oil from anywhere, but rather displacing it through a loop.
Second point is that it is not the only oil port for the return, I also have one for the pinion bearing and one for keeping a big steady flow for the main case itself which port is located roughly by 4th-3rd slider on the left side.
Another cooling circuit will be 4th gear>gundrilled mainshaft (for all the needle bearings) connected to the port that feeds the mainshaft ball bearing.
All return lines will be connected from a manifold fed by the pump.
And last, thankfully others have done it before me with great success.
Gute nacht.
_________________
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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Waldi
Samba Member
Joined: February 28, 2014
Posts: 1752
Location: Germany
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| Posted: Sun Sep 06, 2015 6:55 am Post subject: |
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Your logic thinking should tell you, that becasue of the syncro oil retaining in the bearing shield you will have always more oil in the g-housing, which means you have less in other places.
I am not sure if the oil will not block the vent while driving uphill.
Edit:
Great succses ? Does this mean this gearboxes stand more than 300tsd km no matter how you drive ? |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Sun Sep 06, 2015 11:06 am Post subject: |
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You've already proven your points on other threads about the strength of the Syncro transmission and that discussion with you is pointless, you're basically a troll lurking to stir up sh!t.
Do your thing somewhere else, I'm not interested in debating with you.
_________________
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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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Sun Sep 06, 2015 11:12 am Post subject: |
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Alika, just do your thing.
Your box will be sweet.
Taking the time to try and explain things around here is getting pointless.
Have a safe Holiday and Hang Ten for me  |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Sun Sep 06, 2015 11:33 am Post subject: |
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The week end has started well Dylan 
Barrels of joy, until I didn't make it.
Labor Day fact: Did you know you can fit a 9'8" gun by the sliding door in a Westy without opening the hatch? That's the exact maximum you can, after that, you gotta open the hatch to clear the nose and swing the board's tail in by the sliding door
I wish you a good one too !!
_________________
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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insyncro
Banned
Joined: March 07, 2002
Posts: 15086
Location: New York
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| Posted: Sun Sep 06, 2015 11:42 am Post subject: |
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Oh no 
Enjoy a Kona Longboard Ale instead
Hoping to be island bound for Jan & Feb  |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 10811
Location: Western WA
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| Posted: Mon Sep 07, 2015 10:37 pm Post subject: |
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First time I saw this thread. Alika you are NOTafraidOFit! So few people can do the work you do.
Hawaii's cool, especially when away from the tourist traps. We rented a Happy Campers Westy a few years ago on the Big Island, trip report here: http://www.thesamba.com/vw/forum/viewtopic.php?t=454424&postdays=0&postorder=asc&start=0
Hope to get my trans back together this week then have to fuss with pumps & hoses & wires.
_________________
'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 |
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silverbulletuk
Samba Member
Joined: February 02, 2010
Posts: 206
Location: NW Surrey, UK
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| Posted: Tue Sep 08, 2015 6:19 am Post subject: |
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Dude shreds so bad he bust his stick!
Bookmarked this topic, now that I am joining the UN-1 club
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1986 syncro twin-slider rhd, 3.2S Oettinger wbx6
1990 SA Microbus - Supercharged wbx going in with UN-1 trans.
www.025motorsport.com |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Tue Sep 15, 2015 12:58 am Post subject: |
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You're mounting a UN1 transmission in your bus? Do you have a thread going on somewhere? 
Alright, updates about the work done so far:
I've brazed the shifter plate rivet, although it looked healthy solid
I've used an old low gear housing to sit the transmission in on blocks
Puzzle time, missing a couple bolts after 4 years.... even with the best organisation, stuff disappear: unbelievable....
I heated up the main case with a mapp gas torch at the pinion bearing sleeve then dropped it in. To make sure the pinion bearing was perfectly aligned, I used an old bearing and put it in the case as a mock up and marked the case to line up with the 2 notches that are cut into the bearing to lock up the big nut.
Smooth as pie.Notice the fill plug has yellow gas teflon on the threads. That's to prevent the threads to seize in the case. Simple and effective.
Screw the outside bolt so it comes flush with the internal shifter plate, you don't want it to stick out and be in the way of sliding the shifter shaft in place.
Notice the spring clamp to help holding the fork shaft in place to clear the shifter shaft tabs. Everything needs to be perfectly aligned or it just won't go in.
_________________
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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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Tue Oct 06, 2015 9:00 pm Post subject: |
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Latest update
I installed the Mercedes vacuum actuator I had on hand. http://www.thesamba.com/vw/forum/viewtopic.php?t=454153
I had to re-drill the pin location on the little shaft: to do so, I inserted it in the fork actuator shaft and drilled through while rotating the vacuum shaft to get a 360° groove. Perfect guide
I've installed back the old seal for the gear selector shaft. It helps keeping the rubber boot always expanded bc it slides back and forth on the shaft. Simple and clever 
Collection of thrust washers for reverse gear. I had too much clearance to deal with and had Gears scratching his head while exchanging emails, until I realized I didn 't tightened the pinion bearing nut to torque first. What an idiot I am...
So off I go, with a pair of WBX valve springs to keep the nut tool tight while torquing.
Creatively bracing the transmission on the bench and the wrench tight.
Finished up with a piece of tube cut to length as a spacer to keep the tool super tight onto the pinion bearing nut. Took me a while but I got to the 225Nm torque, and then loosened it per factory specs, then went back to 225Nm and gave it a little more .
Worked and bent on the oil cooler line for 4th gear,mainshaft ball bearing and gundrilled mainshaft. That stainless steel Audi A4 1.8 Turbo oil line is the cream 
De-brazed the bracket off the line
I added a stud to clear the hydraulic fitting elbow for the spray nozzle for mainshaft ball bearing.
Assembling the parts back. I had a feeling I was forgetting something in there, but after a long day at work, I just couldn't see it right in front of my eyes...Find out on that picture why I almost gave myself a 100 lashes a few minutes later.
Tightening the secret bolt behind that cover (that I had sealed up a while ago  Talk about doing the work twice....)
Mocking up the diesel bellhousing with Tdi starter and adapter plate to give me some motivation to keep going
Now, kill me with fire. I forgot the goddamn shift fork for reverse and G gear!!!!
That'll work better now....
I guess the decoupler was done wrong too then... I was questioning myself why when I blow on the vacuum actuator, the decoupler didn't work.... no sh!t kiddo... no dog gear on the pinion shaft, DUH!! That's what happens when it takes 4 years to reassemble a transmission, you forget how things are...
All assembled now. Yay!!
Mainshaft super hard to spin. What now again??
I took the nose cone apart for the 2nd time now. Turns out I didn't correctly design the oiling fitting for the gundrilled mainshaft. It was 2.55mm, and rubbing against the tip of the mainshaft  .
Time for some ghetto lathe action to thin it down a bit.File and drill press will do.
Success!! from 2.55mm to 1.75mm. Yesssss son!!
Installing slightly less thick vitton seals for the output flanges.
I didn't want rubber but they seem to not exist in the original thickness.
Installing the differential.
Installing the Tdi style input shaft.
Somebody asked me a while back a picture of the tools I got from Latvia that I modified for the pinion shaft double tapper bearing race/nut. Next to them is the differential nut tool from Smallcar.
_________________
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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rudolfgreen
Samba Member
Joined: December 01, 2007
Posts: 15
Location: Oahu, HI
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| Posted: Thu Oct 22, 2015 10:00 pm Post subject: |
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Alika this thread is amazing great stuff bro!
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83 Vanagon TDI
04 Jetta TDI |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Mon Nov 16, 2015 9:22 pm Post subject: Re: Alika's Syncro transmission work |
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Thanks Rudolf!
Since I don't like doing stuff like others, I always tweak it my way, I found an oil cooler from a BMW M6 with a mechanical gear electrical pump attached to it.
German stuff, looks like new. It probably will be more reliable than anything elese I could have bought online for that price ($160 shipped).
I will use that in my system and include a second little radiator in serie, this one seems too small in my opinion.
Aloha!
_________________
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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87vanwes
Samba Member
Joined: April 10, 2014
Posts: 204
Location: OBX NC
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| Posted: Tue Nov 17, 2015 3:01 pm Post subject: Re: Alika's Syncro transmission work |
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That trans cooler looks like a great way to go, nice that its all one unit.
I have followed this thread for a while now and love what you are doing.
Can't wait to see it up and going. Threads like this keep me going and it's a
Long road ahead. |
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narendra.vw
Samba Member
Joined: February 07, 2013
Posts: 440
Location: Bangalore India
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| Posted: Wed Nov 18, 2015 6:04 am Post subject: Re: Alika's Syncro transmission work |
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Nicely formed thread. You need to be in VW’s R & D department.
Found a spot in fitting the cute little oil cooler ? Out side engine Bay? |
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icolquhoun
Samba Member
Joined: August 30, 2015
Posts: 92
Location: NJ
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| Posted: Wed Nov 18, 2015 6:31 am Post subject: Re: Alika's Syncro transmission work |
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Looking great!
I'm using the same method to hold my 091 to the bench while I tighten my pinion nut, although I didn't think to use valvesprings to ensure it stays seated! In the future, drill two sets of holes in either end of the c channel so you can have better leverage while loosening AND tightening it. If that wrench slips in the vice you will be hurting! (or the pinion teeth)
If you want an adapter for your TDi starter that's a little more inline with the level of work your doing elsewhere (superb) might I suggest:
keep up the awesome work! |
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svenakela
Samba Member
Joined: July 19, 2006
Posts: 776
Location: Ekerö
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| Posted: Wed Nov 18, 2015 8:35 am Post subject: Re: Alika's Syncro transmission work |
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Don't add another matrix, it is not needed. That BMW cooler will do the job.
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Vanagon mirror end caps |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7300
Location: Honolulu,Hawaii and France
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| Posted: Wed Nov 18, 2015 10:40 am Post subject: Re: Alika's Syncro transmission work |
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Thank you guys
Narendra, the van is not even assembled yet, so I didn't find a spot at this time. I'm thinking on the left side somewhere.
Icolquhoun,I'm not sure I understand your advice, I did drill the C-channel and bolted it to the main case. When I added the piece of pipe to keep the pinion nut tool all the way in, there was no way it was to ever slip out of there
The C-channel stuck under the vise was to brace the transmission from spinning around
I have already a Tdi adapter plate from Germany I got a couple years ago before RMW offered it on the US market. Did you make yours? It looks good
I wish I had a lathe to make little parts like that.
Sven, are you up to the lathe challenge for my coolant flange adapter ?
You really think it's gonna be enough of an oil cooler? The weird shape is not gonna make it easy to get a fan to blow air on it :/
Aloha all!
_________________
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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