Tranny Leaks After Changing Fluid

BugCatcher1957 · Samba Member Joined: April 17, 2006 Posts: 55

Just to close the loop on my problem, I have been informed that the plugs on the earlier VW transmissions were made of cork or rubber, and after 40 years or so, they dry out and disappear. For the later transmissions, VW used metal plugs. Anyway, Rancho Performance Transmissions sells metal plugs for the holes (about $4 per plug). I understand that I can just tap the plug into the holes and problem will be cured. Sure beats dropping the tranny - which is something I really don't want to do.

Thanks for everyone's help in identifying the problem and helping me find a solution.

Dangermouse · Posted: Tue May 01, 2007 9:28 pm Post subject:

Well whew; thank you for clarifying that Very Happy

DrDarby · Posted: Tue May 01, 2007 8:14 pm Post subject:

My '64 was missing two of these plugs and I whittled down two brake bleeder rubber caps and RTV sealed them in place. They've sealed perfecly since about '86. I partially drained the trans down past the holes overnight and cleaned with brake-clean.
_________________
Midwest Autosavers, Inc. Crystal Lake, IL

KTPhil · Posted: Tue May 01, 2007 6:40 pm Post subject:

UPDATE:

Talked to the tranny shop... the photo is actually correct, but it is misleading--the spring and ball go in the hole BEFORE the shift forks. They are not held in by the plugs--they are BEHIND the shift fork and cannot fall out. So you probably have balls; imagine your relief! Wink

The plugs, they say, on early beetles were some kind of cork or fiber material that tended to disintegrate. He says you can machine it to take later plugs, but a good cleaning and a dab of silicone will do the trick.

KTPhil · Posted: Sun Apr 29, 2007 9:51 am Post subject:

I don't think the plugs are plastic. Mine look like an allen head stud. You might find a short threaded bolt (make sure it is short so it doesn't interfere with the forks) and use a copper oil screen gasket under it or maybe a flat washer with a small dab of silicon under it.

I'll ask when I pick up my tranny this week. Do you have the tranny number (stamped on the right side), to be sure they get me the right parts. Year would be good, too.

By the way, that photo I posted seems wrong... the order should be ball, spring, plug, NOT spring, ball, stud. (A few of the VW photos have problems ilke this.)

BugCatcher1957 · Samba Member Joined: April 17, 2006 Posts: 55

The weekend is here, and there is nothing like spending a Saturday night bonding with my VWs. I was able to poke around more and I believe my leak is coming from a missing plug protecting the detent ball and spring. All three plugs are missing and it looks like bottom plug is the primary source of the leak. Thanks for everyones counsel in helping me find the problem.

As suggested by Dangermouse, I did my best to plug the holes with silicone. While I did my best to clean the area (which is not easy with the tranny still in the car), time will tell whether the silcone will seal the hole. No spot under the car this morning, but I have not refilled the tranny yet. I spent considerable time searching the site for a discussion on the issue but I didn't find much. I am somewhat suprised others don't have an issue since it OEM plug was just a piece of plastic which seems vunerable after +40 years.

Anyway, I would like to get a permanent fix on the problem. KTPhil, can you keep me in mind when you talk to your transmission guy. Here is Michigan, there are no local VW tranny shops. I, of course, will be happy to reimburse you. If there is an alternative solution, I would welcome everyones input.

Thanks again for your help.

KTPhil · Posted: Tue Apr 24, 2007 7:56 am Post subject:

I bet a local VW tranny shop has a bunch of them. If you have no local shop, and if you know they are missing and have a tranny number, I can ask at my shop when I pick up my rebuilt unit in about two weeks.

Dangermouse · Posted: Mon Apr 23, 2007 10:03 pm Post subject:

Aha!

(So, not to hijack the thread or anything, but if one of my detent plugs had been missing for a period of time, is there then a chance that I could also be missing a detent ball and detent spring too? Can't say that I've ever felt the transmission snap into position...)

Anyone know if replacement plugs are available from anywhere?

KTPhil · Posted: Mon Apr 23, 2007 8:38 pm Post subject:

They make the shift forks "snap" into position when you shift:

Image may have been reduced in size. Click image to view fullscreen.

Dangermouse · Posted: Mon Apr 23, 2007 8:24 pm Post subject:

Yeah, those. What you said... Very Happy

Leak all over the place, they do.

So, what's a detent ball then Shocked

KTPhil · Posted: Mon Apr 23, 2007 8:07 pm Post subject:

"Access holes"? Aren't those the threaded plugs to hold the detent balls for the shift rods?

Dangermouse · Posted: Mon Apr 23, 2007 7:22 pm Post subject:

If its one of the small (I think 6-8mm) holes, then I had some success with just sealing it up with silicone.

BugCatcher1957 · Samba Member Joined: April 17, 2006 Posts: 55

After crawling around on my back with wire brush in hand, I am no longer sure the leak is coming from the drainage bolt. Let's assume that after I scape 43 years of crude off the right side of tranny and find that one or more of these access points is the source of the problem, then what? Also, what if it is a seal, does that mean a different tranny?
Sad

Dangermouse · Posted: Mon Apr 23, 2007 6:11 pm Post subject:

There are three small access holes up on the right hand side which should normally be plugged. If one one the plugs/caps has deteriorated or is missing, fluid can leak down from there and look like its coming from the drain plug.

BugCatcher1957 · Samba Member Joined: April 17, 2006 Posts: 55

I used 90 wt gear oil, and I filled it on the side filler hole until it started to drip down the side. I believe this is the proper procedure. I didn't think it was possible to over-fill the tranny because you can't fill it higher than the fill hole. As to where the leak is, I will give it a careful inspection after cleaning it the best I can (I can't power wash it at my house) and if it doesn't reveal anything, I will do it again. Good thing I don't make a living at this, because if I did, I would be broke.

If it leaks all over my garage again, then who knows what after I scream.

mailman · Samba Member Joined: March 24, 2005 Posts: 1663

I have no personal experience with this....but I have heard that over-filling the trans can ruin the seals. Could the fluid be running down from the end of the trans and just dripping off at the drain plug?

Changed the fluid in my (new to me) '64 last fall. The trans was a totally filthy mess to begin with, which would indicate previous leakage. I did the fluid change, and now I have obvious wet leakage.

I suspect the seals are leaking, but I'm going to be changing out the trans before long, so I'll just keep an eye on the fluid level for now.... Sad

_________________
'64 Bahama Blue Beetle / steel sunroof
'64 Bahama Blue Beetle Sedan (future ragtop)

Seb67 · Posted: Mon Apr 23, 2007 1:44 pm Post subject:

DrDarby · Posted: Mon Apr 23, 2007 1:01 pm Post subject:

Are you sure it isn't coming out farther up and running down the side of the case to the drain bolt area ?
_________________
Midwest Autosavers, Inc. Crystal Lake, IL

Cusser · Posted: Mon Apr 23, 2007 12:21 pm Post subject:

I'd also sugest teflon/PTFE tape. Actually, I'm quite surprised that thick 80-90 weight gear oil (that's what you used, right???) would be able to leak out past the threads. You didn't use ATF did you?
_________________
1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297

BugCatcher1957 · Samba Member Joined: April 17, 2006 Posts: 55

I am not sure where the leak is, except it is marking its spot under the front drainage bolt. Generally the tranny is caked with crusted grime, except I cleaned it fairly well around the access bolts.

Nothing is easy.


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