Transaxle Clarification for Baja Build

[shetterson]

Hello, long time lurker here, first time poster. I'm planning a baja build this winter and am currently looking for a transaxle. I've always heard of people using 002, 091, and 094 transaxles in their baja's, but only this past week learned of the 091/1, aka the 094 4-speed transaxle. I've found an 091/1 I'm considering buying, and I have a few question.

I know the 094 is sought after for its full size reverse gear. Does the 091/1 have that same full size reverse gear?

From what I understand, the 002 and the 091 have the same engine bolt pattern on the bellhousing, and it sounds like the 091/1 is different since it was used with a water cooled engine. Can I bolt an 002 or 091 bellhousing on the 091/1? I want to use the air cooled engine I have now and potentially get a larger modern water cooled engine later on (I'm thinking honda K24) and a KEP adapter plate.

I would love to get an 094 but that seems unlikely and this 091/1 seems like the next best option. Should I go for it?

[jsturtlebuggy]

Yes the 091/1 has the full size reverse gear as the 094.
The 091/1 and 094 5speed are both what's called a side shifter as shift shaft comes out side of main case on right side.
Weddle Industries sells a bolt on shift linkage that you can use with a couple of U joints and 3/4in tubing can be adapted into your Baja. It will require cutting a hole in body.
I used one in my Meyers Manx Manxter Dual Sport I Built. And it Is Subaru powered.
The bell housing is the same pattern as 002/091 so an air cooled engine could be used.
There even a aftermarket bell housing available that uses stock type 1 transaxle mounts. You will more then likely going to have to fab up your own mount for the front.
The picture shows a 091, 091/1, and a 094 5speed

_________________
Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960

[Schepp]

Build the car as you would like it now, not later.
Why do the fabrication, electrical, tuning and downtime twice?
Its a waste of money building the car as air-cooled if you intend on swapping engines later. Unless of course you have deep pockets.
If the air-cooled engine runs well you could sell the complete engine and use that money to buy the donor vehicle / engine.
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Bandit #19
1972 Baja Rallycross Bug

[shetterson]

Thank you for the information! I forgot to add another question I had. I have been considering making this baja mid engine with the K24 and flipping the transaxle around. I've heard that the ring gear in the beetle trans can be swapped to the other side to reverse the rotation of the outputs. Can you do this in the 091/1? If not, how well would the 091/1 do upsidedown?

What I'm currently thinking of doing is creating two small 1:1 ratio gearboxes, similar to the vw bus reduction boxes, to mount on either side of the trans to reverse the outputs. I have access to free material and machining and have the design skills to create this. My goal is to keep the exterior appearance of the beetle, similar to a class 11 baja but with larger tires, more wheel travel, and more horsepower.

I've decided I will just start doing it all this winter. I hit the jackpot and I actually found someone with a K24 with the KEP adapter plate to mate it to the aircooled trans already! A project they were going to start but no longer have the time for, so I've lucked out.

[jsturtlebuggy]

The 002,091, 091/1, and 094 have offset pinion and ring gear cannot be flopped like a type 1.
In sand buggies I have seen Bus transaxle mounted upside down for mid engine setup.
The mounting bolt hole in bell housing are not the same width apart. with and adapter plate to some other engine it fairly simple to redo mounting points.
Reduction boxes or Portals as they called use on Hummers and others would work for a mid engine setup.
A friend has a setup in a buggy using a IRS type 1 trans and layed down reduction boxes in custom IRS trailing arms using CV joints.
you idea is doable.

Robbie Gordon new V8 powered side by side is using portals in the rear suspension with Albins gearbox.
_________________
Joseph
Fair Oaks/Orangevale, CA
Elrod Motorsports
Motion Tire Motorsports
Having fun with Dune Buggies since 1970
Into Volkswagens since 1960