Rebuilding transaxle with Samba help! 091/1 (fun starts pg 4)

[old_man]

[old_man]

[DanHoug]

iff'n i had a diesel, i'd totally go with straight cut gears. besides, always kinda liked the whine of truck transmissions... part of the music of the road.
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-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com

[erste]

The GT straight cut 4th isn’t loud at all (in a TDI) and I hardly noticed a difference. There’s a kind of “oscillating” noise at certain speeds, but I wouldn’t call it loud. It’s more of a resonant vibration that you kind of feel if that makes sense.
Put as many GT parts into it as po$$ible!

[old_man]

[DanHoug]

[AndyBees]

When you say "straight cut" are those the thick cut gears offered by Weddle? If not, does anyone have links, pics, sources, etc.

I installed a Weddle 3rd and 4th (1.14 and .77) in a DK trans and put it in service, August, 2012. Today, the trans has well over 85k miles on it. The gears have always "whined" when coasting in gear at low speeds (when more audible). I did replace all bearings except the Pinion Bearing. The OE 1st & 2nd gears are quiet as they should be. So, I've never considered the whine to be bearing related........... just gears!

Anyway, my ALH TDI has a Stage 1 Tune. More that 25k of those miles mentioned above were pulling a 1200 lb popup camper with at least another 400-500 lbs of stuff on board. And, one trip there were four adults and all of their stuff.

So, unless the gear(s) had manufactured issues, I doubt the gear gave-up the ghost just because an AHU TDI was pushing it up hill.
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'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.

[DanHoug]

just a little something for those of us that love the whine of straight cut gears!

Link

_________________
-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com

[erste]

[Sodo]

Did you use an OEM 4th gear?
OEM 4th gears can break at “the Weld”.
Syncro stuck in 4th
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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

[old_man]

[jordauto]

Any update on the carnage? I'm finally ready to do the final assembly of mine and was curious as to what failed before I do.

[old_man]

[old_man]

Well here is what I have so far.

Here is a picture of the oil. This is all the oil I drained out. 500ml.

Anyone have an experience with this. Does anyone think there is anything salvageable inside my box including my new R&K and buy peloquin?

[MarkWard]

I recall the 091/1 holds 4 qts. I'd have to check to be sure. Where did all the fluid go? There is zero way to determine what is salvagable without taking it apart and inspecting.

If you have a Peloquin, it's likely salvageable if that's what you are asking. It can be disassembled and cleaned out.

Surprisingly, that's not much on the magnet if it sheared 4th gear.
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[old_man]

[old_man]

I think this is where the oil came from. It doesn't form a seal anymore. I don't know why. Was input shaft moving around, is that possible?

So this is the ring and pinion. It doesn't look polished but it only has about 5K mi on it. No pieces missing. I think I am going to reuse it because I think it's still serviceable and it seems like every supplier is out of stock of this ration.

This greeted me when I took the cover off.

There actually was no bearing left. Just gone.

[?Waldo?]

The outer lip of the input shaft seal is not what keeps the oil in. The inner lip does that. The outer lip just keeps clutch dust out of the seal and likely sealed when the input shaft was centered by the pilot bearing in the crank.

[old_man]

Actually black soot from oil burning. Impressive when you think about it.

I'm not sure where those balls when. I don't even know how they got out. Bearing came out on one piece.

Yup.

4th gear cracked syncro.

The closer the bearing was to the nose the more golden/burnt it was. By the pinion there was no evidence that anything happened.

It's going to be fun washing all of this.

This stupid thing is loose. Oil slinger?

I don't know what to do about this. I guess the ideal would be to get an aluminium gear carrier. It would be nice to reuse it.

In short, I don't know why I would randomly get shuttering when accelerating in 4th after being on the highway for many hours. I assumed it was something to do with my DMF clutch being soaked in oil. Maybe it caused the oil slinger thing to come loose and then it was only a matter of time? Is that a plausible theory?

The way forward:

-Clean clean clean.
-Replace all bearings (It would be nice to keep the pinion bearing but I think everyone is about to tell me that is not a good idea).
-Procure a new 4th gear set, this might prove to be difficult because it is showing out of stock everywhere I look. It's a 0.78. Should I just get a GT straight cut one?
-Put the damned thing back together.

The interesting part is that there is someone a mere 3hrs away that has a spare South African 5 speed. He want's to sell it but only as a package with his Doka. In the long run that would probably be the more expensive option as it would no doubt require re gearing but it is interesting.

[DanHoug]

oh my. my heart cries for you (or your transaxle). if you got only 500ml out of it, it was death by starvation. i have no idea what is salvageable but lots of signs of heat stress. i will be so impressed if this is rebuilt!
_________________
-dan
60% of what you find on the internet is wrong, including this post.

'87 Westy & '89 Westy both 2.1 4spd

Past projects can be found at--
www.thefixitworkshop.com