Manual Transaxle oil cooler bung fittings (homebrew)

[dobryan]

[rmcd]

Next time. Thanks anyway.
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VW LT40 build. Like a Vanagon but 30% larger in every direction and 40% slower even in metric.
https://www.thesamba.com/vw/forum/viewtopic.php?t=749359&highlight=

[vwwestyman]

Hmm, this is very interesting, as I'm constantly worried about the transmission in my '78 with TDI.

When I had it rebuilt/regeared, I asked about the SA oiling plates as I'd seen them here, but it seems that there was no room in the 091 transmission.

This idea seems like a great one to get some more/cooler oil up there in my gearbox too. Can anyone comment on whether the little nozzle/squirter would work for me with an 091?

Because I don't have a shifter linkage to worry about being in the way, it seems like I could also just use the original, simpler version if that is still a possibility.
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Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[Sodo]

[Sodo]

[Pcforno]

[Sodo]

[dkoesyncro]

Very nice! Tom, thanks for your commitment to furthering the potential of our gear boxes.

[tencentlife]

[Sodo]

Members as humble as SteveMC offering expert help freely is what makes theSamba !

That our member gears was willing to risk his nest egg to build stronger gears/shafts/housings (gears) is impressive too. We are lucky for that. Talk is cheap. Collectively theSamba can get these trannies to last longer if we keep pushing forward and keep the ideas coming.

I've been making nozzles for awhile, and selling them (very slowly), so there are NOT a lot of folks building pump-systems (with my nozzles). But I'm almost done with another batch of 6 (for transaxles with no oiling plates).

Oil climb plates (which I don't have) are a significant band-aid that many transaxles have, as the best current option. Pumping oil has to be better, but with no real test, it is ....speculation. And there will_be_no_real_test like an OEM test. Other than time, so you have to wait. And even then...everyone knows about members who like their mods, "they really really like them". So there's that.

Cooling is important only if parts are getting too hot and fooking the oil film (and the oil too) which will happen with big engines driving fast. Clean oil,,,, and/or active filtering is probably the other big contribution to longevity (again.... with big engines driving fast). And better parts.
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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

[erste]

[Sodo]

I think you found a beautiful solution.
The 4wd 094s ( watercooled Vanagons) will be envious of flooding the mainshaft bearing. I don’t know if a similar process can be done on a 2wd watercooled 094.

Not a lot of 091s out there pumping oil though but you could be their hero (w/your builder) for this method.

I don’t understand your worry (yet) about oil leaking out of the shift shaft.
You could tee off and add a fitting to the filler, with a bent nozzle, and squirt a larger portion of the 2gpm at the 4th gear mesh.

Samba members might appreciate labeling pics with their respective transaxle number. So far all the pics have been “094” watercooled transaxles. Now that we’re seeing pics of 091s which may be rare, it might help members to keep things organized if the rare trans had “091” embedded into the image. Or “air-cooled”.
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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]

Oh you`re getting there

For the overflow in the chamber, you can adjust the flow maybe by installing a pressure bypass valve on a tee with a return loop. When it gets too full and force fed, pressure should increase opening the bypass valve.

Oh and you should have enough room with the firewall but not with a straight AN fitting and then an elbow on top of that. Theres foam on the pic you found online, but not that much. I would weld the fitting already at 90* to keep it low profile, then put a straight fitting on that to your hose.
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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

[erste]

[erste]

[Sodo]

ALIKA is visualizing his M24 oil cooler fitting with an M14 banjo on there...

Maybe with a bent 3/8” copper nozzle epoxy’d into Alikas fitting at the correct angle to squirt the 4th gear mesh?

The bearing is reacting the same force that holds the gear teeth meshed. The bearings are a very important element to preserve. I can’t think how to decide which which way to bias the delivery. They will both get a fantastic amount of lubricant.
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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

[erste]

New location (to scale) for the squirter as long as there aren't any issues drilling through that rib. I don't see why there would be. This way I don't have to jack with fittings on top.

For the second nozzle, I just ordered a 3/8" NPT male with hose barb, and the -8AN stainless weld bung just showed up. I like how the 3/8" tubing fits tight in these fittings. EDIT - I'm dumb and should have just ordered another -8 to 3/8NPT from mcmaster...

I do have another M24 fitting from Alika, but would have to order another bolt and union and should have the fittings I need if I go this route (3/8"NPT to -8 with nozzle). 3/8" aluminum tubing will be here today, and that might be easy enough to bend.

[Sodo]

Back to this thread....

Oil level check-hole on the left side of the transaxle.

With an oil pumping system there have been two situations where I lost control of my gearbox oil level.
My oil filler hole has a nozzle in it - and a hose connected to it, so I can't easily confirm the oil level. I have an oil check hole on the nozzle, but there are conditions ……., so wheres the oil coming from, the level, or the hose draining? It can get confusing and messy.

And being a Syncro, you can get confused by the “1 quart” of oil that gets caught up front in the low-gear housing. It can take awhile to 'level' or to drain out. I'm sure that 'lost quart' confuses a lot of folks. Remember you have to lift the front of the Syncro 9-12 inches, then give it time to drain all of the oil out. Maybe hours? I don't know how long it takes but it comes out pretty slow.

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Anyway my trans is "OUT" again (due to the Smallcar input shaft spacer problem from 2009-2011) so I decided to add an oil level check hole on the driver's side for easy access.

Note VW provided a boss right at the oil level.👍🏽👍🏽
Cool.😎😎

^^Test hole drilled on an old case.^^
Nothing in there to hit.
You can poke the drill in about 1.5 inches before it hits a shift rod.

I used a 1/8-27 NPT plug.
I do not worry about magnesium chips anymore.
But I did pressurize the trans to blow out whatever I could while drilling and tapping threads because it seems like poor form NOT to.
But they are so soft, and I filter and change oil often too.
And lotsa folks drive 150,000 miles in terribly contaminated oil while rolling out steel chunks in their gears.
Magnesium is nothing, like brass but maybe even softer.
Magnesium is so soft it might even protect the gears.

Anyway I'm looking forward to the ability to easily confirm oil level.

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That miscellaneous sensor wire is from this project in another thread.
Temperature Control (electric) - Manual Transaxle gearoil cooler
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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

[Sodo]

I like my oil level check hole.
Especially on a syncro, which has a sequestered volume (the low-gear housing up front) that takes oil slowly, then drains slowly,,,,,
…..confusing Syncro owners since 1985. Including me in 2016-2021.
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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

[T3TRIS]