62 Transaxle disassembly/inspection

[anthracitedub]

I have the original transaxle from my 62 beetle that I want to rebuild for use in my 57 Ghia.
The 62 was parked in ‘82, I got it in 2000, got it running and stopping all was well until I tried 4th gear, it jumped right out every time.
I quickly replaced the trans with a rebuilt and stored the trans hoping to use it later.

I figured I would post my progress and findings here and maybe get some advice from the pros as to which direction to go.

I’ve never rebuilt a transaxle before but I have a very strong mechanical background and I’ve been in skilled trades for almost 20 years. I also have the big blue books...also aware of the precise instumentation that is required to set up the function of these units...

So here is a little show and tell.

[img]https://www.thesamba.com/vw/gallery/pix/1738152.jpg[/image

Many years of Oklahoma red dirt and most of the oil that was in the box, took a little work to remove.

You gotta love it! Does anyone recognize this bracket? It has a patent number stamped on it and is made of heavy steel... nice quaility though.

Got the cases clean and the went after the internal goods.

The differential looks very nice, the bearings seem to be in good shape to.p

The pinion shaft and all of its parts seem to be in good order as well... but the real trouble was 4th... these parts didn’t fair so well.

Most of the assembly is great but the 3/4 clutch got hot and discolored, there’s some wear action on the teeth for 4ths hub. I don’t know if the syncros are trash, but they usually get replaced anyway.

You can see the heat action on the fork and the clutch center...

I’m wondering if I can replace the bad 4th gear stuff and reuse the rest. Can I reassemble this transmission using the original shims/set up and get this thing serviceable again?

I’m not concerned with mods or upgrades... just want it stock to use in my Ghia which is a weekend/fair weather type vehicle.

[Casting Timmy]

I don't know if they make any of that early 1-2 stuff anymore, later idlers and slider and hub will give more engagement with the gears. You can cut down a later 1-2 operating rail to the early length if you have to convert it.

Fourth gear popping out will be from the engagement teeth being worn, you will have to check the teeth on the synchro cone of the 4th idler and the inside of the 3-4 slider.

the ring and pinion is you put the shims back it will keep the pattern. I would check the end clearance on the gears and adjust as needed.

[mcmscott]

2nd gear synchro is a 295d, same as third and fourth. The 247a first synchro has been out of production for some time but I believe I have a source for som being repoped. Use a new 3-4 slider, change the hub on 4th, change the pinion bearing to a tapered roller and change the main shaft bearing as well as the 3-4 fork. Set your forks in a fork jig, or equivilent, and you probably will be good to go. (cheapy build)
_________________
There are no stupid questions, only stupid people,

68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

[anthracitedub]

Thank you for the info on the parts, that’s what I’ve been looking at in the classsifieds... wasnt sure on the syncro #s... yeah, just wanted to do a build on the cheap. It’s been great learning along the way.

[[email protected]]

If Scott can't help you out with the 1st gear syncro, it looks like there are some NOS ones in the classifieds.
https://www.thesamba.com/vw/classifieds/detail.php?id=1997762

[anthracitedub]

Awesome! Thank you.

[Dale M.]

Your unknown bracket looks like it may be center pivot for a camber compensator bar... Yes there were many versions as years progresses...

https://www.thesamba.com/vw/forum/viewtopic.php?t=523611

Dale
_________________
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"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ...

[anthracitedub]

Yeah, that’s what I was thinking. When I was looking for trans parts, I seen a newer, cheap empi CC and it was very similar. I thinking mine could be from the Empi era when China didn’t take over most of th production.

I googled the patent number on it but it didn’t fetch any info.

This bracket is made of very thick steel and feels like it has some quaility to it.
If I had the rest of it, I would consider putting it on my 62.

[anthracitedub]

Does anyone know where I can get part numbers for the pieces I need? I think I know the syncro numbers.

I just want to get the parts list and the amount of each that I need so I can get this party started.

This is my first trans overhaul (won’t consider it a rebuild) but really liking messing around with it...more interesting to me than engine builds.

[mcmscott]

I can get anything you need
_________________
There are no stupid questions, only stupid people,

68 Ghia
67 T-1
65 Notch
02 Mexican beetle
74 Thing
15 Long travel rail
07 Nomad
05 f-250

[esde]

[anthracitedub]

My main concern is going to be setting up the shift fork locations and if I change the pinion bearing will I have to reset the pinion depth?

I have mics, calipers and dial gauges... just no special fixtures specific to transmisson assembly.

I did mark the locations on the shift rails, but I know this is not the proper way to set up shift forks.

I was hoping that if I don’t make to many changes I could use all the shims placed back in their original locations.

[Casting Timmy]

Most of the pinion depth shim comes from the ring and pinion set, not the bearing or case. I would start with the same shims, borrow your wife's lipstick and run a pattern when you put it back together. They make grease for this,but you can get away with other things if you clean it off afterwards.

The 1-2 shift fork will be the hard one, I know one guy that did his own years ago by trial and error. You should be able to source a case, or maybe pay someone to set it or be able to use their jig.

[anthracitedub]

I’m going to get the parts and keep moving forward, when I struggle I’ll do research here and with my Bentley. I might be able to get some assistance with the set up when I get to that point.

I cleaned the last of the parts today, now everything is ready for action.

[oldschool5er]

Nice detail pics. since the trans had some miles on it just a suggestion if you have not done it yet but check the intermediate housing for wear in the selector bores.
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[anthracitedub]

After I cleaned up the selectors, I placed them through their bores and there was very little movement. I think they should be ok...probably wouldn’t be hard to make bushings if I had to .

I’m guessing this trans has about 182, 000 miles on it... the car was a very dry, straight, well worn original that showed 82,000 on the clock when it was parked in the early 80’s.

With the wear on the 4th shift fork, they must have held it in gear for many of those miles.

[anthracitedub]

[Casting Timmy]

Don't forget new detent plugs on your order list, your had nothing there as those old phenolic ones rotted out a while ago.

3 big and 1 little

[anthracitedub]

Good call... it didn’t have anything except good ole Oklahoma red dirt in the holes... I’ll pu those on the list.

[Dale M.]