Rebuilding 091 DM transmission (early diesel)

[epowell]

[ZsZ]

[epowell]

Aha... so "bearing spreader" and "bearing PULLer" are the same thing.
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www.edwardpowell.com

[gears]

With all due respect Edward .. transaxle work isn't normally taken on by guys who aren't already versed in engine and/or general machinery repair.

That corroded housing is way beyond something most rebuilders would consider useable in a rebuild .. although it could probably make a suitable jig.
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aka Pablo, Geary
9.36 @ 146 in '86 Hot & Sticky
'90 Syncro Westy SVX
'87 Syncro GL 2.5
https://guardtransaxle.com

[Waldi]

[Waldi]

[Vanagon Nut]

[MarkWard]

My preference would be to build transmissions vs engines. I was always surprised how many dealer technicians shied away from doing transmissions. It was like they were full of spiders and snakes or something.
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☮️

[epowell]

[Waldi]

I have no idea about this "jiig".

Edit:

You can use any kind of r+p for this box.
from newer boxes and from Syncro boxes (i kill you
You just need to cut it.

[epowell]

[Waldi]

Yeah, i was following the post, but i never used it.

Gear is the man

[AndyBees]

For what it is worth, I rebuilt my DK 091 using the Bentley Manual. (almost identical to your transmission)

I only used the Pinion Nut tool, 12 ton press with associated blocks and common bench tools. I did make a tool to remove the adjusting rings.

I did not use a jig (marked the position of each shifter with a very sharp hard chisel and took close-up photos after marking and before disassemble).

I marked the relative position of the adjusting rings for the Diff per the Bentley.

Setting the "position" of the big straight cut reverse gear was the only thing that really had me concerned. Seems clearance from 2nd gear is a maximum of 0.020"

I installed all new bearings except the pinion and diff bearings, upgraded 3rd & 4th gears, new 3rd/4th slider & hub & shifting fork, new Reverse Gears, all new brass syncro rings, and new gaskets.

All stuff above come from Weddle Industries..

I've put over 80k miles on the transmission ... works great. I later upgraded the input shaft to one with larger splines to accept a TDI clutch disc. I also, installed the 0.020" plate to hold bearings in place (aftermarket thingy that I am not sure is worth the effort). Seems I got it from Van-café... requires having 0.020" milled off the shifter cone of the housing.

So, in my opinion, you will be fine with the rebuild.

I suggest:

-Pressure wash the transmission on the outside really clean
-Use containers to place bolts/nuts with labeling
-After removing the bell housing, stand the tranny up so the oil can finish draining over night
-Take a photos as you tear it down
-Have a good work area with plenty of space
-Press is absolutely necessary
-Pressing gears off/on, heat them a little with a propane torch (not blistering hot)

For extremely good references, I'll loan you my Pinion Nut socket at your cost of shipping in both directions.
_________________
'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[epowell]

[epowell]

[Waldi]

I have measured the possition of the forks when i have dissansambled the box.

[epowell]

[Waldi]

Do you have a 5,43 r+p ?

[Waldemar Sikorski]

[DanHoug]

your case is nasty but mine was almost as bad. pressure washed it, painted it with aluminum primer (i know, it's Mg), then Rustoleum gray. it's okay. sandblasting would've been great.

if you have 'the knack' you can do this, and as an instrument builder you probably do. i did my 091/1, first trans ever, and so far so good. did i miss some things an experienced builder would do, sure. but i spent the labor money on parts and possibly ended up with a better trans than if a builder had rushed thru one for me. worst case scenario, you screw up a transaxle. whatever, buy a different one. none of this is like it is flight related, where if you break down, you're quite possibly screwed for life. inconvienient and expensive, yes. life threatening, rarely.

-dan