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RoryGirl
Samba Member
Joined: October 14, 2016
Posts: 985
Location: WestWorld Nanaimo BC
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 Posted: Tue Jul 22, 2025 10:49 am Post subject: Re: Removing 091 gear housing |
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| GoEverywhere wrote: |
...those are cable shift anyway aren't they? That's pretty easy.
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Rod shift from the factory
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1991 Twin Slider VR6
1985 Audi 4k |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Tue Jul 22, 2025 10:54 am Post subject: Re: Removing 091 gear housing |
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| MarkWard wrote: |
| It was a joke. No doubt they failed due to stress. I’m surprised you stripped both gears. A single gear is more common. |
I kinda am as well, especially since I don't feel like I was putting a lot of stress on it when it finally went. I WAS climbing a hill, but I was at low throttle and the turbo wasn't even in boost when it happened. Who knows... |
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MarkWard
Samba Member
Joined: February 09, 2005
Posts: 18725
Location: Retired South Florida
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| Posted: Tue Jul 22, 2025 11:00 am Post subject: Re: Removing 091 gear housing |
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Found the photo of the cable shift adapted to the Subaru transaxle. Search is a little bogged down at the moment.
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Tue Jul 22, 2025 11:03 am Post subject: Re: Removing 091 gear housing |
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| MarkWard wrote: |
Found the photo of the cable shift adapted to the Subaru transaxle. Search is a little bogged down at the moment.
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I was actually just doing some research on this. Apparently a company called Zero Decebel makes one for use in the Factory Five kit cars with the Subarugears transmissions (Mid engine version though) that looks really nice.
Its priced at $399 which doesn't seem terrible for what it is. They've got shifters too that might be worth looking at. |
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MarkWard
Samba Member
Joined: February 09, 2005
Posts: 18725
Location: Retired South Florida
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| Posted: Tue Jul 22, 2025 11:09 am Post subject: Re: Removing 091 gear housing |
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| This was a factory five car. It came to me to sort the Electromotive Engine Management that someone else installed. Never saw it completed. |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Tue Jul 22, 2025 11:36 am Post subject: Re: Removing 091 gear housing |
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| MarkWard wrote: |
| This was a factory five car. It came to me to sort the Electromotive Engine Management that someone else installed. Never saw it completed. |
Ahh so same sorta idea. I'm curious how well yours shifted, that adapter arm for the side/side motion is REALLY long. Seems like it would make the throw side to side crazy short. |
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MarkWard
Samba Member
Joined: February 09, 2005
Posts: 18725
Location: Retired South Florida
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| Posted: Tue Jul 22, 2025 12:27 pm Post subject: Re: Removing 091 gear housing |
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| Only drove it on the Dyno. The attachment points/length will control the throw. Years ago, a member in Europe adapted a Vanagon transmission to cable shift. I recall he used a shift lever from another German vehicle. I downloaded the pictures at the time. I don’t think I saved the link. Maybe someone else did. |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Tue Jul 22, 2025 12:35 pm Post subject: Re: Removing 091 gear housing |
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| MarkWard wrote: |
| Only drove it on the Dyno. The attachment points/length will control the throw. Years ago, a member in Europe adapted a Vanagon transmission to cable shift. I recall he used a shift lever from another German vehicle. I downloaded the pictures at the time. I don’t think I saved the link. Maybe someone else did. |
I always thought you aught to get a lot nicer shifting with cable shift on these things. I've never found the rod shifters to be particularly nice shifters even when well serviced (Which mine is not!). There's a good chance I'll tackle a cable shift conversion after my trans swap. Gotta get some cash back into the "crap I broke it" fund first  |
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AndyBees
Samba Member
Joined: January 31, 2008
Posts: 2623
Location: Southeast Kentucky
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| Posted: Tue Jul 22, 2025 7:56 pm Post subject: Re: Removing 091 gear housing |
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I've been following along...
To disassemble and reassemble your DK transmission,
-You'll need a specialty tool or fabricated one to remove the side adjusters at the diff
-You'll need the big specialty Socket to remove the pinion bearing nut.
-A jig to set the Shifter Forks (it's possible to mark them, but do you feel lucky)
-The jig is very important in setting Reverse Gear
-A means to push the pinion and gear stack out (I fabricated the tool)
-Pinion holding tool for the Race Nut (1st gear race)
-A Bentley Manual for torque specs, etc.
Likely the end shifter cap is wallered which requires milling and the use of a bearing thrust plate (less than $12 from Weddle).
You should replace the bearings for 1, 2, 3 & 4th gears and the bearings on each end of the main shaft and pinion shaft.
The Reverse Idler Bearing is no longer available new.
A new 4th gear set from Weddle at about $465 (3rd gear set would be the same price).
For excellent shifting, you should replace all the synchro rings with the Molybdenum Coated ones (about $100).
Without further details, I just received an order from Weddle for a DK I'll build this coming winter. The price for the parts was almost $1500, including shipping.
Since the transmission obviously has the OE gears, I wouldn't trust anything to have been replaced. Do it right.
Look at the pics in my FB account that I linked to you in a PM.
Side note: At Weddles website, you can click on Tools and see everything but the Jig.
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'84 Vanagon Tin-top, ALH TDI, two trips to Alaska, 2014 & 16. 1989 Tin-top unmolested.
1983 Air-cool, 225k miles, 180k miles mine, seven trips to Alaska from 1986 thru 2003. 1975 Bay hopeful. |
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ALIKA T3
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Joined: July 30, 2009
Posts: 7179
Location: Honolulu,Hawaii and France
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Kdj
Samba Member
Joined: January 28, 2017
Posts: 259
Location: Naptown
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| Posted: Wed Jul 23, 2025 8:20 am Post subject: Re: Removing 091 gear housing |
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| Quote: |
| You could get a UN1 transmission made by ZF for a Delorean too (Renault, Alpine, Lotus). They're "cheap", NOS still available from DMC. |
In the big picture of things that does seem cheap!  Link to DMC
https://deloreanindustries.com/4-1-0-manual-transmission-assy/
Could be another option |
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 4158
Location: MD
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| Posted: Wed Jul 23, 2025 8:42 am Post subject: Re: Removing 091 gear housing |
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It would need an adapter plate, clutch/flywheel, mounts, axles, shift linkage figured out? Anything else?
It is a good idea though. It is already in the right direction. 5 speed. Any ideas on the durability?
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Wed Jul 23, 2025 8:50 am Post subject: Re: Removing 091 gear housing |
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| 4Gears4Tires wrote: |
It would need an adapter plate, clutch/flywheel, mounts, axles, shift linkage figured out? Anything else?
It is a good idea though. It is already in the right direction. 5 speed. Any ideas on the durability? |
Yeah actually... And its a side shifter too which aught to be fairly easy to work out...
I worry a little bit about DMC's world famous (lack of) reliability but that could actually be a fairly solid choice depending on the transmission's actual length.
Kennedy will make you an adapter for practically anything so that would solve the adapter, flywheel, and clutch if the price for a one off wasn't too high. |
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7179
Location: Honolulu,Hawaii and France
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| Posted: Wed Jul 23, 2025 11:01 am Post subject: Re: Removing 091 gear housing |
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These transmissions are made by ZF, very strong. They were very popular in Europe bc you could find them anywhere and mount them in all sorts of kit cars, buggies, Transporters... You can reverse the rotation by flipping the differential, that's how it was made to suit the various applications.
The weak link will be the input shaft coupler. Use the UN1 coupler. The VW splines kinda match, but their profile is slightly different. I stripped a VW coupler before. So I tinned a VW input shaft to press fit it into the ZF coupler.
You always cut it in half to weld to whatever you like and have it gas nitride treated.
I also broke the differential doing donuts, so I upgraded to a 4 satellite diff from a UN5 transmission, it's from a Renault Master van, but this transmission can't be reversed, the diff is too big to flip.
There was a now closed company in GB making better shafts and 6 speed kits too.
The adapter plate is super easy to do to a VW, I did it.
Not sure on other applications.
Gilo engineering used to make a bellhousing for them in South Africa, I think to mate to a Ford engine.
Worth researching.
Bus Projekt in Germany was making kits for the T3.
There were shifter cable kits for them too. I just bolted the T3 selector on the UN1 selector.
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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 |
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Kdj
Samba Member
Joined: January 28, 2017
Posts: 259
Location: Naptown
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ALIKA T3
Samba Member
Joined: July 30, 2009
Posts: 7179
Location: Honolulu,Hawaii and France
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| Posted: Wed Jul 23, 2025 11:50 pm Post subject: Re: Removing 091 gear housing |
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Oh, it looks like GT racing came back from the dead, that website was gone, although I don't see parts for sale anymore. These were the guys with better shafts and 6 speed kits I was drooling over like 15 years ago.
_________________
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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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Jul 24, 2025 8:30 am Post subject: Re: Removing 091 gear housing |
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| ALIKA T3 wrote: |
These transmissions are made by ZF, very strong. They were very popular in Europe bc you could find them anywhere and mount them in all sorts of kit cars, buggies, Transporters... You can reverse the rotation by flipping the differential, that's how it was made to suit the various applications.
The weak link will be the input shaft coupler. Use the UN1 coupler. The VW splines kinda match, but their profile is slightly different. I stripped a VW coupler before. So I tinned a VW input shaft to press fit it into the ZF coupler.
You always cut it in half to weld to whatever you like and have it gas nitride treated.
I also broke the differential doing donuts, so I upgraded to a 4 satellite diff from a UN5 transmission, it's from a Renault Master van, but this transmission can't be reversed, the diff is too big to flip.
There was a now closed company in GB making better shafts and 6 speed kits too.
The adapter plate is super easy to do to a VW, I did it.
Not sure on other applications.
Gilo engineering used to make a bellhousing for them in South Africa, I think to mate to a Ford engine.
Worth researching.
Bus Projekt in Germany was making kits for the T3.
There were shifter cable kits for them too. I just bolted the T3 selector on the UN1 selector. |
Those seem like a really fascinating swap. I wonder what it would take to get that off the ground for something that could be easily swapped into our VWs. It seems like it would be even better than the Subie boxes if it could be worked out.
I was snooping a thread this morning where you were talking about installing one, looked really interesting. If I didn't need to get my rig back on the road I might be tempted to start playing. |
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Sodo
Samba Member
Joined: July 06, 2007
Posts: 10627
Location: Western WA
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| Posted: Thu Jul 24, 2025 8:59 am Post subject: Re: Removing 091 gear housing |
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A 6-speed small-truck gearbox with OEM replacement parts available, would be a dream (for 2wd).
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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 |
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GoEverywhere
Samba Member
Joined: December 13, 2020
Posts: 893
Location: Portland, OR
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| Posted: Thu Jul 24, 2025 9:10 am Post subject: Re: Removing 091 gear housing |
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| Sodo wrote: |
| A 6-speed small-truck gearbox with OEM replacement parts available, would be a dream (for 2wd). |
For real. While I appreciate what Subarugears is doing with their work other options are always good...
I DO have a friend with a whole yard full of Vanagons he's parting out I'm sure he'd let me use to moc things up... But I need to remind myself I don't have time to build a new gearbox kit |
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