Alika's Syncro transmission work

[icolquhoun]

[ALIKA T3]

Oh I see! Well, that was the only piece of C channel I had laying around
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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

[svenakela]

[furrylittleotter]

Looking good. Forgetting parts does keep us humble....

I agree with Sven. That cooler is perfect. Keep it simple.

Neil2

[ALIKA T3]

Thanks Otter

I will still test the flow see how much GPM that thing gets. I'm a little worried about cooling performance though, but we'll see
_________________
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

[ejimmi]

Alika, did you end up using this method? I can't tell in the 2nd photo if it is attached to the pipe that goes across.

[ALIKA T3]

Hi!

Yes I did, I'm missing a few pics and work to post it:

Here is the line going from the gundrilled mainshaft to the 4th gear oiling port

Redrilled the banjo a little bigger.

It's a stainless steel 8mm line for an Audi 1.8T engine that I cut and bent.
Glued with special compound to a modified round flare and a modified banjo fitting.

I don't have a pic yet of the stud installed, it's basically a gundrilled M10x1.25 bolt on which the hexagonal head has been modified to receive a brazed femalle threaded flare to attach to the nut on the steel line pictured above.

On that stud is a long 10mm IDx18mm OD sleeve from a Subaru belt tensioner roller that got bored partially at 1/2" ID to act as a chamber.
The line from the mainshaft ball bearing oiling port rides across it and will be brazed like a tee on top of the sleeve that will be like a banjo fitting.
The stud will be drilled to be like a banjo bolt.

_________________
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

[Sodo]

Alika do you have pics of how you made the groove in your pinion bearing?
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'90 Westy EJ25, 2Peloquins, 3knobs, pressure-oiled GT mainshaft, filtered, cooled gearbox
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered gearbox
....KTMs, GasGas, SPOT mtb

[ALIKA T3]

[Doka Todd]

Bringing back an old one...

Alika did you get this up and running? I'm about to embark on case modifications for oiling and am wondering how that bmw assembly worked out. I have access to one and it seems like a slick all around solution.

I've been scouring the forums and you and Sodo are to be thanked for laying this stuff out. Between you guys, Gears, and the well documented efforts of Herman you've made it so much easier for the rest of us.

[ALIKA T3]

[Doka Todd]

Thanks Alika. I'm likely going the way of the Exa pump (weddle etc.) as it's a proven part. The BMW setup was so inexpensive comparatively that I really wanted it on the short list.

I've been having some conversations with other members on the direction I'm taking with this rebuild, and as I've said to them, I really need to thank and commend you and the others on the documentation and experimentation you've conducted getting an oiling system to work properly. I have design experience, and am a machinist by trade and am fully aware of the expense of time and money that comes with this trial and error. You guys have made this easy for me, drilling and tapping holes is easy when you know where they need to go.

[ALIKA T3]

[ALIKA T3]

Here is a little update from the work I did a few months ago, I had more pics but I lost my phone

I got some 8mm stainless steel tubing. The manifold-T above theLow gear housing has been machined in France last summer, it is hollow inside, to make a little oil chamber, and the bolt that goes through it is gundrilled and has ports like a banjo bolt. The mini T manifold has smaller ID on the outer edge than the inner edge for machining purposes.

Banjo bolt drilled at 60° , offset on the length to preserve strength

The last pic with the tube bent on the ground goes from the access hole for the pinion bearing oiling port, right side of tranny, above tranny and down to the big rectangular manifold, the rear side of it. The opposite forward entrance of the manifold will be the feed from the pump. The manifold is drilled and tapped bigger on the inlet side for machining purposes to create a chamber.

The big oil dump fitting with the blue tape will have a flex line to the manifold, you cannot see the port but it is horizontal and will go through the black aluminum angle profile that supports it. It will be sandwiched with copper washers, bc the mounting holes were too close to clear the fitting hexagonal part, I screwed up the manifold design, I didn't think of that....

Here is the Syncro diesel gas tank mounted and a view for the clearance above the transmission:

I banged the chassis beam with a sledge hammer to gain a couple precious millimeters for the fitting on the end of my gundrilled mainshaft.

_________________
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