62 Transaxle disassembly/inspection

[scrivyscriv]

Thanks for sharing your experience, with good photos too!
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Robert in Memphis
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If you're ever in the Memphis area, you are welcome to stop by for advice and help.

[anthracitedub]

Ok, just wanted to put a period on the end of this journey. I got my 4th set and a gasket kit and went back through the trans installing the new gear set.

Got to go back over the adjustments of the forks and all that good stuff.

I found my oil leak issue that I thought were the detent plugs... turned out to be the nose cone was not flat... this was a new aftermarket part.. don’t know the manufacturer but you can see where that info was milled off by the supplier..still a nice piece, just wasn’t flat where it should be.

I placed it on my true stone with some 320 paper... it took a ton of sanding to get it there.

You can see the corner area below the shift rail area... that’s the leak.

I also had a weird creaking noise in third I figured that out as well...the grub screw for the shift coupling was touching the pan in third as the engine/trans moved in its mounts (new German mounts) . All I did was grind the edge of the grub to gain clearance.

Test drive went really good... nice shifts and no noise! I do have a little scuffing going into second from third.... if I go slower it’s not a problem... not sure what the cause is... new sychros, just doesn’t seem to be slowing the shaft down during shifts.... maybe get a little time on it things will be better or thicker gear oil ? Using 80/90 right now...

Over all, I’m good... have a nice trans, clean, no leaks and finally a synchro first! That’s what I wanted all along.

[anthracitedub]

Let me rephrase... I’ll be singing, trans will be doing exactly what it’s supposed to do 😁.

[mcmscott]

[mcmscott]

[Clatter]

Singing usually means a backlash issue with the ring & pinion, right?


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Bus Motor Build

I have excellent news for the world...
There is no such thing as patina.
It does not exist!

[anthracitedub]

I just got a set in the mail this morning lol. Ill have this thing back together this weekend and this time around it will be singing, now that I’m an expert😁

[nshaddox]

Dude I have tons of stock 4th sets here in Detroit. Let me know if you want one.

[pilottangocharlie]

I appreciate you starting this thread. I’m just beginning to tear down a 65 swing axle to get the same hands on learning.
_________________
Tyler

[anthracitedub]

Got around to pulling the gear off today... thought I’d document my mistake to potentially keep another novice from doing it as well.

As shown, you can see the differences in shoulder diameter. The smaller shoulder goes up towards the pinion nut... wish I would have caught this mistake, would have saved some time and money.

[gears]

I'll be danged if that 4th gear isn't flipped .. larger diameter shoulder normally goes toward 3rd. I used to flip them the other way when I machined for a thrust washer, but that was with a new gear set.
_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

[anthracitedub]

Well, I see that Weddle has gears in stock so I’ll go ahead and order a set, too bad I just ordered some other stuff from them, I would have liked to gotten all the parts in one shot.

If I can get this straightened out, I should finally get what Ive been aiming for... what a journey it has been😊

[[email protected]]

Judging from this picture, it does appear on the pinion shaft that the thinner thrust surface of the 4th gear half is sided toward 3rd, and the thicker thrust is on the bearing side in the carrier. It's been a while since I've had a keyed pinion 4th geared trans apart, but the later trans have the thicker diameter towards 3rd. I would start looking for another 4th gear. The opposite wear pattern now in the gear will still cause a whine after it's flipped. The split case gears are different, so you will need an .89 4th from say, 61-67. The gears aren't going to line up perfectly when in the set up jig/trans.

[anthracitedub]

Alright, I took the gear stacks out of the carrier. Everything looks really good except there is a wear pattern on 4th gear set that I would have remembered seeing on the first assembly.

You can see a striated pattern on the teeth. There is no texture to it and it is pretty much uniform throughout.

What caused this to happen? Could it be the adjustment of the concave washer? Or could it be a misalignment between the two shafts?

I attempted to lay the shafts together with a similar amount of offset as they are when assembled in the carrier. I just noticed that the gears are not on center with each other.

Should I try to shim the shafts so the gears are riding closer on center with each other?

I was able to tweak a few other details for the reverse and have it looking a bit more stable when shifted.

I also polished my referbished shift fork for 3/4... it had a bead blast texture to it.

Also noted that my 3/4 shift rail is the reason behind my stiffer feeling shift in those gears... it is all in the detent... just a tough spring.

Lastly, does anyone know if my 4th gear set from my 57 split trans work in the 62 trans?
If I figure out the root cause for the wearing problem, I can take my 4th hub and put it on the gear from the 57... gotta get this thing put together soon.👹

[anthracitedub]

Sounds like a plan... I’ll drop’em out and get a better look at what’s going on... I really was hoping it would be obvious... but it’s gotta be sometihing minor with major results.

[DeathBySnuSnu]

Without having my hands on it I can not tell you what it needs.
My experience is limited with vw trans but is great with a large amount of other mechanical things.

I would say take the nuts off and drop the stacks.
Get an eyeball on the bearings and thrust. You said you thought it squalled.

[anthracitedub]

Yeah, I used all the original set up on mine... so you think maybe a little more shim in the stack could be helpful? I must admit... w/o all the proper setup equipment, I knew I was shooting in the dark, just hoping that I would get lucky using the existing shims.

[DeathBySnuSnu]

The last time mine went together it felt a lot like you describe and I imagine if I ran it it may have acted the same.

The endplay on 4th tightened up to a loose zero on the thrust washer.
Felt stiff to turn and get the slider to engage.
Once I loosed the nut all was good....knew then it was too tight.
Tore it back down and one more shim.
Note.....mine is a mix and match assembly so it is a given that it may need more shim work.

[anthracitedub]

There are a few close ups of 4th earlier in the thread. Not particularly looking at the gear teeth, but looking at the hub teeth. I do recall the teeth looked real smooth because I sat and brushed all that stuff clean by hand.... seen nothing like what is pictured above, they all had a smooth, polished surface to them.
Not saying there wasn’t 1 million miles on them, but not gouges or major pitting.

[gears]

.
Orientation is correct. Do you have a way of taking a close-up photo?

_________________
aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com