Author Topic: Transmission, Starter & Axles - removal, checkup and reinstall  (Read 21990 times)

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Offline jayson.devries

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I just thought I'd post a running thread of pics of my transmission adventures.

Originally I hadn't planned to remove the transmission; I was just going to check a few things change fluid and then throw the engine back in.  Well once I was under the car I noticed my CV boots were pretty well rotten so the axles had to come off.  I figured a couple more bolts and I'd pull the whole transmission, clean it up and give it a thorough checkup.  Not quite sure how far I'll go with it but I'll post pics along the way.

To start, all grimy and still in the car:









« Last Edit: 10 January 2011, 03:54 by jayson.devries »
1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #1 on: 10 January 2011, 03:46 »
Still grimy but out of the car:









1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #2 on: 10 January 2011, 03:49 »
The cleaning has begun.  Using Simply Green and every kind of brush I can find.





1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #3 on: 10 January 2011, 03:50 »
Almost done with the cleaning:





1973 1303 Autostick
1984 930
1985 Iltis

Offline 68autobug

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #4 on: 11 January 2011, 14:31 »


Very nice and clean...
Now... the BIG questions..??   
what color will You paint the starter motor??
what color will You paint the gearbox??
what color will You paint the bottom plate?

I notice you have a drain plug in the plate...
all My drain plugs are in the gearbox bottom...
never actually noticed one in the plate before..
so they actually changed the gearbox and took the drain plug out...

I replaced the two axle seals in the gearbox... and the two plastic discs... only because I stuck a screwdriver in them to get them out..lol

Lee in Australia







-- Helping keep Autostick beetles on the road --
   -1968 Silver metallic 1600 single port Beetle - with BOSCH  SVDA and new BROSOL H30/31 carburetor with GENIE Extractor exhaust system with a quiet thunderbird muffler

http://photobucket.com/68autobug

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #5 on: 17 January 2011, 18:10 »
Well Lee, there is no question that you have the most colourful Autostick in the southern (and northern) hemisphere.  :)

But no worries, I have no plans to contest your title - I'm going for the "au naturel" look.  However I do have some concerns about corrosion so I'll be (re)painting some parts and will likely fog or "RustCheck" the whole thing.
1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #6 on: 17 January 2011, 18:14 »
...and more dirty parts:





1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #7 on: 17 January 2011, 18:15 »
One of the four CVs was bad:

1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #8 on: 17 January 2011, 18:17 »
Bellhousing off:





Gotta replace the main drive shaft seal:



1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #9 on: 17 January 2011, 18:19 »
Looks like the clutch has been sitting a bit too long:





Time to replace it anyway (down to 7.2mm):

1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #10 on: 17 January 2011, 18:21 »
Axle flanges off so I can replace the seals:



1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #11 on: 17 January 2011, 18:23 »
Starting to get things cleaned and repainted... Lee, this should make you happy - I little bit of bling.

Front mount:

1973 1303 Autostick
1984 930
1985 Iltis

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #12 on: 17 January 2011, 19:12 »
Just to give folks an idea of what's involved in this undertaking... your experience may/will vary. :)

In my case, so far this is what I'm replacing, where I'm getting the stuff, and roughly the cost:

1x   Sachs clutch                        135 USD          TheSamba.com Classifieds
1x   Release ("throwout") bearing   115 USD          TheSamba.com Classifieds
1x   Main drive ("input") shaft seal  15 USD            eVWParts.com
2x   Axle flange seal                     7 USD each      eVWParts.com
1x   CV joint (OE)                        60 CAD            cip1.ca
4x   CV boots w/ grease               10 CAD each     cip1.ca
2x   CV lock ring                          1 CAD each      cip1.ca
1x   Nose cone boot                     7 CAD             cip1.ca
2x   Rear mounts                         9 CAD             cip1.ca
1x   Pan gasket                           8 CAD             cip1.ca
1x   Torque converter seal            23 CAD            cip1.ca
1x   RH12W vacuum hose              21 USD/meter   Belmetric.com

1x   1" copper crush gasket for drain plug        local
2x   oring for bellhousing studs                      local
1x   M20 spring lock washer for frame horn       local
3liters 80W90W GL5 Hypoid gear oil                local

...plus degreaser, cleaners, grease, paint, shipping, taxes, etc ...I'm up to about $500CAD
...plus beer, well let just say a bit more than 500 :)
1973 1303 Autostick
1984 930
1985 Iltis

Offline 68autobug

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #13 on: 21 January 2011, 05:30 »
Starting to get things cleaned and repainted... Lee, this should make you happy - I little bit of bling.

Front mount:



Holy Cow Batman....
look at that color...... Metallic too....   and I only have Gray ones...
so, Jayson,  You have beat Me on front mounts.... lol
Excellent job...
axles are also easy too...   and the clutch servo...
I'll have to be into the metallic colors now....  ;D

Those prices Jayson are the cheapest I've seen anywhere...

that ball in the CV joint was bad I use MOLY lithium based grease in CV Joints and anywhere else..

I see You are using Belmetric hose...  Too hard to paint those... lol

cheers


LEE in Australia



-- Helping keep Autostick beetles on the road --
   -1968 Silver metallic 1600 single port Beetle - with BOSCH  SVDA and new BROSOL H30/31 carburetor with GENIE Extractor exhaust system with a quiet thunderbird muffler

http://photobucket.com/68autobug

Offline jayson.devries

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Re: Transmission, Starter & Axles - removal, checkup and reinstall
« Reply #14 on: 31 January 2011, 02:04 »
New clutch disk and throwout (release) bearing arrived.


http://picasaweb.google.com/jayson.devries/1973VolkswagenSuperBeetle#5568142757956825682


http://picasaweb.google.com/jayson.devries/1973VolkswagenSuperBeetle#5568144494437797538

Old clutch (VW #001 141 031X) on the left, new one (SACHS #1864 241 003) on the right.


http://picasaweb.google.com/jayson.devries/1973VolkswagenSuperBeetle#5568142762971144530

I was surprised that the new SACHS clutch is only about 8mm thick.  There was probably still a lot of miles in the old clutch but I figured I might was well replace it while I'm at it.


http://picasaweb.google.com/jayson.devries/1973VolkswagenSuperBeetle#5568148849326697858

New throwout bearing on the right (SACHS 3151 136 001) is identical to the original (left).


http://picasaweb.google.com/jayson.devries/1973VolkswagenSuperBeetle#5568143873407121666


http://picasaweb.google.com/jayson.devries/1973VolkswagenSuperBeetle#5568143881248227202
1973 1303 Autostick
1984 930
1985 Iltis