transmission recap (long)

[rapieper@yahoo.com (Ron Pieper)]

One slight correction, we replaced 1, 2, and 3 synchros.  

Finding a cracked brass cone behind a driveaxle flange is actually
pretty common.  I do agree the Peloquin kit is nice.

The rivet heads had smeared some aluminum from the case over the pinion
shaft race, and the bearing was shot.  Getting the race out was almost
impossible - I had to end up grinding the sucker out (grrr).  It's the
first time that the gas grill trick didn't work, but those were
extenuating circumstances!

Given that and a few re-dos (oops did we adjust 5th gear?, etc.), it
was not my easiest rebuild!  But I'm confident that all will be OK, and
I'll sure take care of Wes if something goes wrong!

BTW list, if you ever have the chance to beg Wes's help, do it!  He's
fantastic to work with.  Calm, competent, and bright.

Later, 

Ron

--- Wes Brockway <KYWes@bellsouth.net> wrote:
> This is long but hoped to give info to others who aren't familiar
> with this information.
> 
> Thanks to the expert help of Cheapass Ron I got my AGB tranny rebuilt
> last Monday but it was an all day job. I think I slowed Ron down. My
> troubles were hard shifting but no grinding noise and no slipping out
> of gear.
> 
> As we opened the tranny we found the gears, bearings, and synchros in
> good condition. However when we looked at the differential we
> discovered that I was deep into the SMS syndrome. Two rivet heads had
> already come off. We found one and I guess the other got ground up.
> We also discovered that one gear on the ring gear had been broken
> off. Pushrod looked ok, just a little worn. The biggest concern was
> that the SMS had ground the case around the pinion gear race and had
> made cuts into the case around the differential. As it looked I was
> not far away from a total destruction of my tranny. Luckily I had
> already planned on repairing the SMS and ordered a bolt kit from
> Peter and a Peloquin  80% LSD kit. Oh, we also found one of the
> factory slip rings in the differential was broken. There was all
> kinds of metal in the case requiring a good cleaning. The magnet,
> which I had no idea the tranny had, was covered with metal fragments.
> The metal was so pervasive that the detent dogs on the fifth gear (we
> didn't check the others) were filled with metal.
> 
> I should also note that I had already found that the rear tranny
> mount was sheared in two and had replaced it. After removing the
> tranny I found the driver's side mount was cracked. I've not had time
> to check the right side yet but I pre-purchased one figuring it too
> is bad. My local machine shop pressed in the left mount for the
> transaxle for $16.00. The mounts came from Potterman.
> 
> We went ahead and replaced the 2,3,4 sychros and of course the bolt
> kit and LSD kit. The Peloquin LSD kit is one nice piece of work. Very
> well done with excellent instructions and definately a better job
> than VW did.
> 
> I've yet to get the tranny put in but am looking forward to sweet
> running shifts. I've no idea when the rivets first went or how long I
> drove it with two off. But much longer and I'd have had a hole in the
> case.
> 
> I have already replaced the shifter bushings. New motor mounts should
> help. The transmission work is doable in one's garage but there are
> homemade speciality tools needed and a couple of tricks. If I had
> tried to do this without Ron's help I'd have probably given up. The
> two main tools Ron had made were one to split the case consisted of
> two pieces of angle iron. On drilled and tapped for a bolt that
> pushes against the other angle iron laying  on the main shaft bolt.
> Two other holes were drilled to run two fifth gear housing bolts
> through as guides. 
> 
> The other tool is a gear puller with longer pieces made so as to
> reach all the way to the end of the main shaft gears. The hooks are
> put under the gears and the pulling bolt is placed against the
> mainshaft bolt hole.
> 
> Other tools are pretty standard.
> 
> Some things I've learned about hard shifting.
> 
> Check all the motor mounts and replace as necessary.
> Replace the shift bushing, ball and align the shifter.
> If the transmission hasn't been rebuilt then do it as soon as
> possible. I almost lost my second tranny to SMS.
> 


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