The Berg 5 Speed Thread

[Root_Werks]

Wanted to start a thread specifically for Berg 5 Speed conversions. There are a few build threads out there, but no real one-source for experiences, trail and errors etc.

I'll start with my build (which I had to twice):

Rhino case, Super Diff built for a Swing.

Originally built with gears:

3.78, 2.25, 1.56, 1.22 .89 on 3.88 R&P

I ran this setup for about 1,500 miles and just didn't like that 4th was close to 3rd in the RPM spread. So out the transmission goes to a different builder more local to me.

Current gears:

3.78, 2.25, 1.48, 1.04, .82 on 3.88 R&P

The RPM spread is SO much nicer and if I need to, can run 60MPH in 4th for long freeway grades too steep for the .82. Keep the head temps down. I've been running these gears for 500 miles and loving them. So far, no head temp issues in 5th on long freeway runs.

I'll see if I can get a few pictures up.

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When I set my timing, why do I flush, then take a pee?

[Root_Werks]

Installing the 5spd in the Bug was fairly straight forward. The biggest challenge was ensuring the transmission didn't make any contact with frame or body. Just shoving the trans into place would have hard contact on the body under the back seat at the seat belt mounts and torsion bar tube at the mount area.

Required using a jack to push the seat belt mounting plate up a little and cutting/welding the torsion bar tube to create a dimple.

No good pictures of the two clearance mods and I'm certain every Bug would be a little different.

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When I set my timing, why do I flush, then take a pee?

[Root_Werks]

Here's a picture of stock 4spd and Berg 5spd with Rhino case. A bit of size difference. Rhino case with 5spd weighs a bit more. I should have weighed the two transmissions. I'm guessing 25lbs more.

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When I set my timing, why do I flush, then take a pee?

[Glenn]

Here's some info on my Berg 5.

Builder - Gary Berg
Case - Volkswagen "Rhino" case, heavy duty side covers
Mounts - Gene Berg GB-642P heavy duty rear mounts and Gene Berg GB-643F front crossmember
Gear Ratios - Close ratio 1st, 2nd, 3rd, 4th and 5th, steel shift forks, hardened keys
1st - 3.78:1 (heavy duty, late model)
2nd - 2.06:1 (stock, late model)
3rd - 1.58:1 (welded hub)
4th - 1.21:1 (welded hub)
5th - 0.82:1 (welded hub)
Rev - 3.61:1 (stock, late model)
Differential - ZF, Limited Slip (LSD) with 4 spyder gears (11 tooth)
Ring / Pinion - Gene Berg GB-660K-3875 (Klinkenberg), 3.875:1 ratio, 8 bolt
Shifter - Gene berg GB-5710, 5-speed shifter, new shift rod bushing
Axles - Type 181 Stub Axles and C/V Joints with Sway-A-Way Axles
Lubrication - Valvoline Gear Lube, 80-90W API Service GL-5 and MT-1 rated
Misc. - Heavy duty cross shaft (welded), GBE Super Duty Pinion Bearing Retainer, Welded Clutch tube




Pictures of the build: https://www.glenn-ring.com/berg5/

Updated by Gary Berg

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Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"

Member #1009

#BlueSquare

[Root_Werks]

Glenn,

I think I remember you saying you ran a regular Super Diff for a while before swapping to the ZF. If so, did you have issues with noise from the Super Diff?

Under load, I'm getting a little noise in 4th and quite a bit in 5th. Quiet under decel, just under any load. 1-3 are quiet.

I'm wondering if that's a product of either the Super Diff (Extra lube holes drilled) or just low quality gears?

-Dan
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When I set my timing, why do I flush, then take a pee?

[Glenn]

This is why I replaced the Super Diff with the ZF.

_________________
Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"

Member #1009

#BlueSquare

[Root_Werks]

Oh boy, I'll check for little chunks of metal when I change the oil.

Good shot of the mid-mount. A must for the 5spd conversion. Easy to install, after final fitting of the transmission, installed the little rubber mounts, set the metal tabs on top, welded in place.

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When I set my timing, why do I flush, then take a pee?

[Bruce]

[Bruce]

[Glenn]

[Root_Werks]

[Bruce]

[gears]

.
Since we're side-tracking, stuffing 930-size spider/ side gears into early ZF:
.

.

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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

[six7vdub]

What is a roundabout cost for going with a decent 5 speed build? Reading through this thread I see that there are upgrades that some have went with, so i'm just looking for a general number on a 5 speed that would be putting power down for a mild 2276 with roughly 180hp.

[67rustavenger]

[Root_Werks]

[Glenn]

When I had mine rebuilt, I was told to insure it for $6000. That included the upgraded parts and the ZF LSD. That was 12 years ago so add a few $$$
_________________
Glenn
74 Beetle Specs | 74 Beetle Restoration | 2180cc Engine
"You may not get what you pay for, but you always pay for what you get"

Member #1009

#BlueSquare

[Olli from NJ]

Don't forget the mid-mount and the shifter. About another $500.
The thing to really take into account if one is serious about a GB5, is the potential wait on GB. My GB5 build was completed recently and the wait on GB supplying the builder the kit was 19 months. And the builder was told at the time of the order that they (GB) were ready to start a production run. My builder ordered 3 kits.

My GB5; IRS, Rhino case (gusseted), 4.12 R&P, 3.75, 2.25, 1.58, 1.14, .89 all gears are Weddle except for the .89 which is German OE. Quaife diff, 930 out put flanges, all internal components are REM polished.

Street Ghia. 25.2" rear tire. The engine is a 235 HP 2387 (with the belt on and muffler) power band is 3900-6500+

Olli

[SilverThing]

[Bruce]