On today's transmission adventures......

[balljoint]

After being 90% sure it's not a shift plate, rod etc adj issue as it actually grinds going into 2nd and is not trying to go into reverse, I had a look through the filler hole and can make the 2nd gear synchro basically kiss 2nd gear when pushing it with a pick.
Now I know I'm only pushing one side and it's not 100% accurate to get a measurement as per bentley spec, but I think this way still shouldn't allow one side to kiss with everything being totally assembled and all.
Also you can see the synchro just remain up against the gear even with no pressure applied.

https://youtu.be/PtfosjUM1uI

So now Im thinking I need to get in this box but of course need you guys opinion first!
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

Yes, that synchro is wasted
_________________
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

[balljoint]

Fun times ahead!
Got to fab up a press to remove the main shaft and if I need to get anything else off as well after further inspection.
Will 10 ton be ok?
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

yes you need a decent press, also a fixture or cut case to set the forks
_________________
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

[balljoint]

So luckily I was able to get my hands on an early 6V case with the 4 bolt pinion retainer and 2 drain plugs.

My case is an AO 12V with 4 bolt pinion retainer and 2 drain plugs.

Will I be able to cut this 6V case and use it as a jig to set up the forks? Are the clearances/bolt up etc for the gear set the same between the two?

6V case

_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

[balljoint]

Great! Really slim pickings for these things where I am.

Thanks again man.
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[balljoint]

So finally got things rolling.
2nd synchro confirmed shot...measured up to 0.33mm.

Now I'm dealing with a non US swing axle tranny here and I'm guessing 68-69ish so I'm back and forth between 2 bentley manuals.
I noticed they state a larger synchro clearance up to 1.9mm in the 70-79 book and only up to 1.0mm in the older 66-69 book. Is it because of the different design of synchro?
Wear limit however is the same.

What also jumped out at me is the placement of this dished washer. I found it on the pinion shaft as pictured but to me it doesn't do squat there.

The old bentley doesn't have it pictured on either shaft but the newer bentley has a dished washer between the circlip and 4th gear thrust washer on the main shaft.....so I guess the guys who were in there put it on the wrong shaft?

Any tips on measuring up synchros? It's hard to get a proper reading with that side to side rock!

1-4, L-R
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[67 Sunroof]

What is the synchro and why is it shot? (Is it in the picture)
Newb questions!!!
_________________
1776cc, CB crank, CB 2241 cam, CB light lifters, CB H-beam rods, CB light flywheel, Mahle forged pistons, A1 Sidewinder exhaust, Dellorto drla 40’s, Hoover modded case, fully balanced, fully flowed, heads by www.type-emotorsports.com, Air ride suspension by https://www.airkewld.com/?Click=3989

[GARRICK.CLARK]

Take a look at the corrosion where the side plate gaskets go. Use a good sealant

[Ohio Tom]

Yeah, that washer doesn't belong there.

[mcmscott]

New pinion bearing, 2 113 311 269b synchros, 2 113311295d synchros, mainshaft bearing, check/change 3-4 slider, 3rd hub on 4th and 4th hub modified and on 3rd.
_________________
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

[balljoint]

No problem using the later 120* synchros on these early gears?
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

The 1-2 gears in your pic appear late
_________________
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

[balljoint]

From the 66-69 bentley the 1st and 2nd synchro described is exactly like mine.
1st has a narrow shift plate groove and 3 oil grooves between them.

2nd has wider shift plate groove and 2 oil grooves between them.
Both have same inner diameter and can be exchanged so the manual says don't mix them up

Weddle has the following which long enterprises recommend for 1st AND 2nd for late (66-6 swing axle, and I was going for this.

Can the later 113 311 269B you recommend be used instead of the 113 311 269A?
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

269a is a first gear synchro, 269b is a second synchro that will replace the 269a. Most builders, myself included, use 269b for first and second gear so as to not have to stock exess invatory. What you need is what I posted.
_________________
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

[balljoint]

Great!
As for 3rd hub on 4th and 4th hub modified and on 3rd,
I guess would be for use of the better condition dogs on 4th in 3rd position right?
3rd has space to press off but how the hell do you get off 4th?
And how do you modify 4th hub?
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[mcmscott]

[balljoint]

Actually both my 3rd and 4th has some wear on the drive side of the flanks

3rd also has some minor pitting here and there as can be seen.

What do you suggest?
Pressing off that 4th on those edges got me anxious already!
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi

[balljoint]

3-4 slider is new...well just about 80miles on it.

The hub has no id marks on it, the slider has a line and a notch as can be seen to the right of the orange mark.

What direction does each face.? Need to make sure, as clearly the guys who were in there wasn't too sure of what they were doing.
_________________
It's an ongoing journey, never forget where you came from....

65 rhd Beetle
72 rhd kombi