Alika's Syncro transmission work

[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.

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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

[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]

[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]

[Sodo]

Alika do you have pics of how you made the groove in your pinion bearing?
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'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

[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

[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]

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

[furrylittleotter]

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

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

Neil2

[svenakela]

[ALIKA T3]

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

[icolquhoun]

[ALIKA T3]

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

[svenakela]

Don't add another matrix, it is not needed. That BMW cooler will do the job.
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Vanagon mirror end caps

[icolquhoun]

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!

[narendra.vw]

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?

[87vanwes]

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.

[ALIKA T3]

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