Broken Syncro Front Transmission Mount Ear

[caseyl]

Hey Samba,

It looks like I broke this ear on my syncro transmission. Has anyone had any success welding this cast mount?

I could probably get creative and made a specifically shaped washer instead of welding.

Is the standard procedure to disassemble the case prior to welding?

I have a tig welder and would probably do it myself. Does anyone know what rod works best?

I believe the case is a later model (1990-1991 or so) aluminum one.

Thanks in advance everyone. I was pretty bummed out when I saw this.

[Sodo]

All low-gear housings are aluminum and its a weldable aluminum.
It's a HUGE job to weld that.
You don't have to disassemble the trans.
But the trans has to come out.

The Low gear housing is NLA.
I hope you kept the broken piece, can weld it back on at trans rebuild ( or 3rd/4th hub replacement ! ) time

This mount is a simple function, but it requires BOTH ears.
It not only supports the trans - it resists output torque (to the front-prop-shaft).

I would fab a rectangular steel "washer" that nestles into the recess, just bridging over, with a 'leg' tacked on to make up for the missing aluminum ear (if that makes sense).
Maybe with Permatex Ultra-gray sealing between the steel and the aluminum.

If you have an aluminum-welder-guy, it could be made from aluminum.
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[crazyvwvanman]

I've had a broken and missing ear welded back before.
My tranny guy had a donor ear to have welded on.
Those low gear housings can get badly cracked in the bearing area so then a bad one can become an ear donor for another.

The tranny was taken out of the van but wasn't opened up when mine was welded.

Mark

[MsTaboo]

https://www.germantransaxle.com/product/pioneer-machine-werks-low-gear-housing/
_________________
Currently:
'90 Syncro Westy 3 knob w/Zetec

The information age has morphed into the age of disinformation and willful ignorance. Agnotology!
All that's needed for evil to prevail is for good people to do nothing.
Resist Kleptocratic Oligarchy (and Idiocracy)!

[4Gears4Tires]

Well that's not cheap at all.

I'd try to get some angle iron, flat iron, or bar stock and make some sort of sleeve to go over the arm.
_________________
'87 Syncro Ferric Oxyhydroxide Superleggera Edition
'85 Westy Sciuridae Domus Edition

[dhaavers]

[zerotofifty]

[markswagen]

that's as maybe, but when you are on hells revenge and a bunch of razor side by side drivers get upset because the were taken out on an ''extreme trail'' because there are fucking volkswagens everywhere.
no sir, you can keep your jeep, the engine is in the wrong place anyway.
FWIW, my syncro transmission has had both support tabs welded back on, no idea the story behind it, it was long before my caretakership.

[Sodo]

syncro is expensive.
But you can't wake up in a jeep

in a beautiful, almost inaccessible campsite,
sit up,
open the stove
make coffee

[zerotofifty]

[zerotofifty]

[Sodo]

OK then, UNCLE !
Bet you can't sleep or make tea in a Razor.
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[MarkWard]

OP, I might have a cracked case I would sell on as a donor. PM me if you need to go that route. I’ll wait to hear before digging it out.

[WiboBusMan]

[?Waldo?]

[caseyl]

Thanks for all of the replies everyone. Hopefully soon I can drop this transmission and get a better look at the damage.

I will be sure to update the thread with the fix.

[zerotofifty]

If you be welding the repair, consider adding some more metal so in as to beef it up better than stock, perhaps likewise on any other ear. Evidently other folks have these break so it is a design weakness.

If you do all the prep work, adding some more reinforcement should be little extra effort.

Anyhows, that be what I be thinking of doing. Dont let this happen again.

good luck, keep us informed on your fix.
_________________
Sorry About That Chief.

Give Peace a Chance.

Words to live by.

[Phishman068]

I haven't welded an ear on a syncro transmission- but I do teach welding, and have disassembled some transmissions. I definitely think you could weld it on without disassembling the entire transmission/getting it rebuilt. Just gota get it clean, get a little heat in there, work it fast with lots of amps, then cool it down before the heat can move to much- but even then..... transmission cases move heat around, that's what they do, I wouldn't personally worry about warping anything.
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http://www.thesamba.com/vw/forum/viewtopic.php?t=559766&highlight=winter+rust
http://www.thesamba.com/vw/forum/viewtopic.php?t=482402&highlight=sunroof+syncro
http://www.thesamba.com/vw/forum/viewtopic.php?t=569774
http://www.thesamba.com/vw/forum/viewtopic.php?p=6864936#6864936

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