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AlteWagen
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PostPosted: Wed Jul 06, 2016 4:27 am    Post subject: Official WTF Transmission do I have/should I get thread Reply with quote

Focus will be on Type I swing and IRS from 61-79 and Type II from 61-67 EXPORT (U.S.), other markets varied considerably. I wont go into 60 and earlier split cases, 68 and later bus boxes, automatics, or autosticks as those should be topics all to themselves.

Additional info on available gear ratios both stock and aftermarket will also be discussed as some regular posters seem to cut and paste their response to “freeway flyer” questions without giving any usable information beyond stating that it’s a marketing term originated by a now bankrupt business.

Sorry still no trans code listing but since the majority of axles you will come into contact with today are far from virgins The likelihood of the components being what the were when they left the factory is very low which makes the codes virtually useless.

Pics have been collected from various sources, ads, gallery, google images etc. If your pic is used and you wish it to be removed just let me know and Ill find one to replace it or list owner info if provided.


This other transmission thread has been going on for some time now with great info but since its in the offroad forum many don’t even know it exists.

http://www.thesamba.com/vw/forum/viewtopic.php?t=143138

Ill copy the basic identification info from the first post here as the pics and descriptions are pretty good and add a bit more specific data that people seem to ask for over and over.


Identifying VW Transaxles

Type I 1960 and earlier AKA split case
Image may have been reduced in size. Click image to view fullscreen.



Type I 1961-79

Swingaxle 1961-1968

1961-1966
Short/Short axle
4.375 r&p
3.80 1st
2.06 2nd
1.32 3rd
0.89 4th


1967
Short/Long axle
4.12 r&p
3.80 1st
2.06 2nd
1.26 3rd
0.89 4th


1968
Long/Long axle,4 lug brakes
4.12 r&p
3.80 1st
2.06 2nd
1.26 3rd
0.89 4th


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joescoolcustoms wrote:
Three sets of axles for a type one swing axle:

Short Axle / Short Spline up to 1966. 3 5/16 inch from bearing sholder to spline end
Long Axle / Short Spline 1967 only. 3 15/16 from bearing sholder to spline end
Long Axle / Long Spline 1968 only.

Two sets of axle tubes:
Short tube 3 3/8 inch from spring plate mounting surface to backing plate mounting surface
Long tube 4 5/8 from spring plate mounting surface to backing plate mounting surface

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




AutoStick
1968-197?
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IRS-Early Dual Side Cover 1969-1972

1969-1972 Beetle
4.12 r&p
3.80 1st
2.06 2nd
1.26 3rd
0.89 4th

1971-1972 Ghia
3.87 r&p
3.80 1st
2.06 2nd
1.26 3rd
0.89 4th


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


IRS-Late Single Side Cover 1973-1979

1973-1979 Beetle
3.87 r&p
3.78 1st
2.06 2nd
1.26 3rd
0.93 4th

1973-1974 Ghia
3.87 r&p
3.87 1st
2.06 2nd
1.26 3rd
0.89 4th

*Note: The one on the left is from '75-up, and the one on the right is from '73-'74. As far as I know they are the same except for the case differences.
Found in the '73-up Bug. They have a 3.88 R&P ratio.
Image may have been reduced in size. Click image to view fullscreen.

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Type II 1961-1967
Swingaxle with Reduction Boxes

1961-1963
Small nut (36mm) reduction box 1.39:1 ratio
4.12 r&p
3.80 1st
2.06 2nd
1.22 3rd
0.82 4th

1963
One year only "1 ton" brakes with 1500 engine
Small nut 1.39 or 1.26 with 1500 engine
4.12 r&p
3.80 1st
2.06 2nd
1.22 3rd
0.82 4th

1964
Big nut (46mm) reduction box 1.26
4.12 r&p
3.80 1st
2.06 2nd
1.22 3rd
0.82 4th

1965-1966
4.37 r&p
3.80 1st
2.06 2nd
1.22 3rd
0.82 4th

1967
4.37 r&p
3.80 1st
2.06 2nd
1.26 3rd
0.82 4th

*NOTE
Optional "Alpine" or "Mountain" gearing in the early small nut reduction box was available at a 1.60 ratio. More common in European market but sometimes seen here in the states. 55mph @4000 rpm with stock tires? You might have mountain gearing in them there boxes!

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

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Type II 1968 and up

The first Bus IRS trans in 68 is called a 113 type Bus trans. Same for those up to 71. This is because all the parts associated with the 4 forward gears and reverse are exactly the same as what are found in a Beetle 113 trans. Exceptions are gear ratios and tooth configuration.

Then in 72, the 002 Bus trans came out. The individual gears were all completely re-designed and are called 002 gears. These were used to the end of 75. Beetle gearboxes with only one side cover also use the exact same 002 Bus type gears.


The 002...Aka the 3-rib
*Note: The earlier 3-ribs have no mounting ears on top of the bellhousing, axle flange retainers attached by acorn nuts, and a shorter input shaft (for the T1 engine). There's more info the early models posted below the pic. They have a 5.38 (Also 5.42, but it is pretty rare) R&P ratio.
Image may have been reduced in size. Click image to view fullscreen.



The 002 5-rib
*Note: Even though the 5-rib has a few different components than the 3-rib, it's still classified as a 002.
Found in '74-'75 Bus. They have a 4.86 R&P ratio.
Image may have been reduced in size. Click image to view fullscreen.



The 091...Aka the 6-rib
Found in '76-'79 Bus. They have a 4.56 R&P ratio, and are considered to be the strongest stock VW transmission.
Image may have been reduced in size. Click image to view fullscreen.



091-Side Shift
*Note: This is the one that can be converted to nose shift.
Essentially the same as the Bus 091 and can be converted to nose shift.
Found in '80-'83 Vanagons with the T4 engine.
Image may have been reduced in size. Click image to view fullscreen.



091-Mid Shift
*Note: This one cannot be converted to nose shift.
This may actually be an 094 instead of an 091, but I haven't verified this yet.
Found in '83-up Vanagons with the Wasserboxer engine.
Image may have been reduced in size. Click image to view fullscreen.



Bus/T3/T4 Automatic
This one happens to be a late Bay or early Vanagon. Note the shifter on the right side. Early ones had the shifter on the left.
Image may have been reduced in size. Click image to view fullscreen.



094 Synchro 4x4
*Note: I don't know much about this one, except for the fact that they are pretty rare. However, they have a locking differential that can be made to fit in an 091 or 002 (More on this later).
Found in ??-?? Synchro Vanagons.
Image may have been reduced in size. Click image to view fullscreen.



Vanagon Diesel
No information available at this time.
Image may have been reduced in size. Click image to view fullscreen.


edit: removed "super"
edit: added swing axle length info
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PostPosted: Wed Jul 06, 2016 4:29 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

WTF is a “Freeway Flyer”?

Freeway Flyer is a term used by builders to describe a transmission with a taller final drive ratio than designed from the factory. By using a taller (numerically lower) ring and pinion or 4th gear it allows lower engine rpm at higher speeds.

For vehicles originally equipped with a 4.37 r&p and a .89 4th gear (61-66) this would mean installing a 4.12 r&p or a .82 4th gear

1967-1976 Type I transaxles had virtually the same final drive ratio and the only way to get higher speeds is to add a taller 4th gear (.82 to the 4.12 or .89 to the 3.88 ).

One thing to consider when using a taller 4th is the spread or gap between the 3rd and 4th gears. Too much of a spread and you will have to rev the engine pretty high before going into 4th. If using a lower hp engine when you hit a hill you are going to be miserable having to shift back and fourth. Having to rev super high or lugging the engine will not help mpg or engine longevity. Know your torque curve and discuss proper 3rd gear choice with your builder.


For a bus it depends on the year as different r&p and reduction box ratios are used. These days finding a true bus transaxle with its factory 3rd and 4th gears is fairly difficult and expensive if you do. Today most builders use a type one core and flip the differential to the other side of the case for use with reduction boxes.


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


with the availability of 3.44 R&P even more combinations are available.

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




There are many factors involved when deciding what gear ratios to use in your particular application such as engine torque/hp, tire size, vehicle weight, aerodynamic properties, and desired cruising speed. Its been my experience that at least 100hp is needed to pull taller ratios than VW used in late model transmissions especially if any grades will be encountered. Tall gearing combined with low HP/Torque is a recipe for disaster.


Another extremely important issue to consider is the heat generated from the additional load and lower fan speeds (remember lower engine rpm = lower fan speed). In order to compensate, using a Porsche 356 alternator pulley or larger crank pulley will bring fan speed back up and help increase cooling. Having ALL the correct factory tin in place is essential on a stock vehicle and even more important on a performance build pushing taller gears! Adding a venturi ring helps quite a bit as does using industrial tins when heater boxes are not installed. Do not forget to use the thermostat flaps even if not using a thermostat as they direct the cooling air to the cylinder head where its needed most.


I always insist on using engine instrumentation to monitor engine health even on mild builds. When altering factory gearing it is an absolute NECESSITY!!! Cylinder head temperatures should be monitored as the added load/heat will quickly destroy your heads if you are not careful. Oil temp gauges are not enough to ensure engine safety, OT and CHT are two independent variables that are slightly related and should be monitored separately. Oil pressure is more related to oil temperature and should also considered. A tachometer is a useful tool to see where your specific combo works best and will allow more accurate tuning of the final drive ratio especially when different tire sizes come into play.


This spreadsheet allows you to plug in all the different variables and gear combinations to see what might work best for your application.
http://www.thesamba.com/vw/archives/info/rgb_calc.php
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PostPosted: Wed Jul 06, 2016 4:55 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

I'm going to say 2 things.

The term "Freeway Flyer" is just a fancy marketing term used in flashy magazine advertisements by a company that went bankrupt. VW never gave any transaxle a name.

There is nothing that was only used in "Super Beetle" transaxles . All the parts and gears were also used in standard Bugs, Ghia, Things, Type II and type III's
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PostPosted: Wed Jul 06, 2016 6:17 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Very informative transmission thread. Standard type 1 and Supers have the same trans. just like vwracerdave says.
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PostPosted: Wed Jul 06, 2016 9:47 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Good to know on the late SSC. Owners manuals no longer provided gear ratio information from 72 on and the few late standards Ive worked on had dual side cover transmissions. Thinking back they were euro versions (73-74) and the 75? federal was far from original so probably got it swapped out at some time. Were standards available in the US after 75?

Anyone have any factory literature for 72 up transmissions?
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PostPosted: Wed Jul 06, 2016 9:51 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

vwracerdave wrote:
I'm going to say 2 things.

The term "Freeway Flyer" is just a fancy marketing term used in flashy magazine advertisements by a company that went bankrupt. VW never gave any transaxle a name.

There is nothing that was only used in "Super Beetle" transaxles . All the parts and gears were also used in standard Bugs, Ghia, Things, Type II and type III's



Exactly
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PostPosted: Wed Jul 06, 2016 10:10 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Scott, I am very interested in any input you may have. Information you provide is usually very helpful and your experience appreciated.

I did not include any info on Things or Type III as I have no hands on experience with these models.

It was interesting to see that 72 things with dual side covers had a 3.87 r&p and .82 4th. Id guess its a euro spec since the US only got them in 73-74. Anyone know the ratios for the 73-74s?

It seems 73 was the last year for Type III, were gear ratios for this SSC trans any different?
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PostPosted: Wed Jul 06, 2016 10:23 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Here is some technical stuff, need to get back to working on it.

http://www.shoptalkforums.com/viewtopic.php?f=50&t=148432
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PostPosted: Wed Jul 06, 2016 10:48 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Thanks for the link, the more info the better!

Thought Id put this here anyway

Pfc J wrote:
This link used to work and have lots of numbers stuff. http://irelandaircooled.20m.com/custom4.html
Here is the trans section, I have no idea how acurate it is.

http://irelandaircooled wrote:

TRANSMISSION CODES
AA 1200 4.375 from chassis No 0 981 810
AB 1300 4.375 Up to 8/70
AC 1500 4.125 Also some 1300 from 8/70
AD 1200 4.375 Limited Slip Differential (LSD)
AE 1300 4.375 Limited Slip Differential (LSD)
AF 1500 4.125 LSD up to 8/70; also some 1300 from 8/70
AG 1200 4.375 Type 147 (Fridolin)
AH 1500 4.125 IRS suspension from 8/68
AH 1600 4.125 8/69-8/72
AK 1500 3.875 Type 181 Trekker up to 8/70
AK 1600 3.875 Type 181 Trekker from 8/70
AL 1500 3.875 Type 181 with LSD to 8/70
AL 1600 3.875 Type 181 with LSD from 8/70
AM 1300 4.375 Saloon and Cabrio from 8/70
AN 1600 3.875 Karmann Ghia IRS from 8/70
AO 1600 3.875 Karmann Ghia from 8/70
AP 1300 4.375 LSD from 8/70
AQ 1600 4.125 LSD 8/70-8/72
AR 1600 3.875 K-Ghia LSD from 8/70
AS 1600 3.875 Type 1 from 8/72
AT 1600 3.875 1303S and Cabrio from 8/72
AU 1600 3.875 Ditto with LSD
BA 1300 4.375 Semi-auto from 8/68-8/70
BA 1500 4.375 Semi-auto from 8/68-8/70
BC 1300 4.375 Ditto with LSD
BC 1500 4.375 Ditto with LSD
BE 1600 4.125 Semi-auto from 8/70-8/71
BF 1600 4.125 Ditto with LSD
BG 1300 4.125 K-Ghia semi-auto from 8/70
BH 1300 4.125 Ditto with LSD
BJ 1300 4.375 Semi-auto from 8/70
BK 1300 4.375 Ditto with LSD
DA 1500 4.125 Type 3 swing-axle to 8/68*
DA 1600 4.125 Type 3 swing-axle to 8/68*
DB 1500 4.125 Ditto with LSD*
DB 1600 4.125 Ditto with LSD*
DC 1500 4.125 Type 3 with IRS from 8/68
DC 1600 4.125 Type 3 with IRS from 8/68
DD 1500 4.125 Ditto with LSD
DD 1600 4.125 Ditto with LSD

*Note that reinforced swing-axle design was available on
post 8/68 Type 3 models as an option (M263)

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PostPosted: Wed Jul 06, 2016 2:36 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Most of those Internet transxle code charts have mistakes in them.

73-74 type 181 Things (USA market) "AV" code came with a 4.125 R&P with 3.78/2.06/1.26/.93 gears. Another myth about the Type 181 sold in USA is they did not have an LSD. It was an option buy very, very rare

Type III SSC transaxles came with a 4.125 R&P with 3.78/2.06/1.26/.89 gears.

Later '72 type I was a transition housecleaning year when changed from the DSC cases to the SSC cases and also the 3.80 to 3.78 1st gear mainshaft. You could have any combination of the 2 depending what parts were on the assembly line. "AH" code had a 4.125 R&P and the "AT" code had the 3.875 R&P.

There is some dispute as to when Ghia's actually did get the 3.875 R&P gear some say 71-74 while others say 73-74. When they did get the 3.875 R&P gear they kept the .89 - 4th gear making them taller geared then a Bug because of the more aerodynamic body style.
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PostPosted: Wed Jul 06, 2016 4:25 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Thanks for the corrected info.

The 71 Ghia owners manual showed the 3.87 which surprised me as I thought it was only 73-74

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PostPosted: Thu Jul 07, 2016 4:59 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

You can delete out a lot of the bus and autostick pictures if these aren't going to be covered.

The 73-74 ghia didn't have a 3.87 first
The 60's and 70's the first gear was either 3.80 or 3.78. Early swing had a narrow geared 3.80 then in 67? they went to the wider 3.80 mainshaft that also uses a clip instead of the nut. Then next was the "super beetle" mainshaft with the 3.78 used in T1, late 3 ribs, and 5 ribs. The 091 they made the idler wider as well as the teeth on the mainshaft, but still a 3.78 first. This is why people can put an 091 idler with the "super beetle" mainshft.

The 75 and later irs besides having a different case also got at some point during those years 091 parts. Fine spline 091 reverse gear and shaft, 091 mainshaft bearing, and 091 big pinion bearing. That may hve also been about the time they went to the lined 1-2 clutch hub that doesn't take spacers. I'm terrible with remembering so will have to check my notes.
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PostPosted: Thu Jul 07, 2016 8:31 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Lets stop this myth. Lets stop calling the 3.78 1st gear mainshaft a Super Beetle mainshaft. They used the same mainshaft in standard Beetles, Ghia's, Things, Type II and type III. There was nothing, not one single part that was only used in Super Beetles. That Bankrupt company also used that term to steal money from people.
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PostPosted: Thu Jul 07, 2016 10:00 am    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

We now have all been educated to the fact that VW never used the term "Freeway Flyer" and that late main shafts are not "Super Beetle" only parts.

Builders who are still in business continue to use the term FF and this post was created to point out the different ways one can achieve a taller geared trans which allows lower RPM at higher (freeway) speeds.

I dont think any builder is trying to steal from anyone by calling a late splined mainshaft a "Super Beetle Mainshaft". My guess would be that here in the US there were a lot more super beetles around compared to other models and when sending someone to get cores from the junkyard it was easier to tell then to get a super beetle trans.

What I have seen is some shops recommending a lower r&p for "drag racing" and taking a SSC trans as a core and giving back a DSC 4.12 with early mainshaft in return. To me that is stealing unless a greater value on the core was given.
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PostPosted: Thu Jul 07, 2016 4:16 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

vwracerdave wrote:
Lets stop this myth. Lets stop calling the 3.78 1st gear mainshaft a Super Beetle mainshaft. They used the same mainshaft in standard Beetles, Ghia's, Things, Type II and type III. There was nothing, not one single part that was only used in Super Beetles. That Bankrupt company also used that term to steal money from people.


There are two 3.78 1st gear mainshafts, should we call them short and long 3.78's? While the "Super Beetle" mainshaft was a poorly chosen nickname it denotes only one mainshaft.
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PostPosted: Thu Jul 07, 2016 6:09 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

but my beatle has the big shaft..and my beatle is oh so super too.... Rolling Eyes so..what company gets credited for the super main shaft& FREQUENT FLIER TRANI'S? I had an older trans with the big shaft and newer trans with small shaft&K 3.88&.88 4th.... they are what they are what dif does it make if I call my super diff super dave or just bob. it seems disassembly is the only way to see whats what ...thats if you can identify it.
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PostPosted: Sat Jul 09, 2016 1:02 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

I saw this list in another thread thought I would add it here even though there are some inconsistencies against factory literature for late split trans.

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PostPosted: Sat Jul 09, 2016 1:51 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Too bad you couldn't delete all the wrong info on Type 3s in that chart. I'd like them to show me a 77 Type 3!

AlteWagen wrote:

It was interesting to see that 72 things with dual side covers had a 3.87 r&p and .82 4th. Id guess its a euro spec since the US only got them in 73-74.

That tall R&P with the tall 4th gear in the Thing also had reduction boxes to tame the gears down. Three years ago when I was in Guatemala, I pulled apart a 73 Thing with reduction boxes and found that same 3.88 R&P.
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PostPosted: Sat Jul 09, 2016 1:59 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

AlteWagen wrote:
I dont think any builder is trying to steal from anyone by calling a late splined mainshaft a "Super Beetle Mainshaft".

No, but the layman might think they are.
Happened to me: A guy wanted a gearbox built for his hot street car. We both agreed it needed the "Super Beetle" first gear. When I charged him extra, he protested because his core was the original gearbox from his 72 SUPER Beetle, so he assumed he already had it.
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AlteWagen
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PostPosted: Sat Jul 09, 2016 1:59 pm    Post subject: Re: Official WTF Transmission do I have/should I get thread Reply with quote

Yeah, I noticed the Type III stuff too.

Bruce, do you have any info you would like to add to the topic? Any other corrections?

I would like to have the most accurate data sheets as possible as to not continue to spread misinformation. I plan to put as much info as possible into a spreadsheet and post at the top for quick reference.

I think most of the confusion is due to the fact that VW had many different applications for different parts of the world and with the internet involved info can be from anywhere.
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