Re: Replacing synchros

[Dan Bubb <jdbubb@ix.netcom.com>]

Yep! The bolt kit is a damn good idea. You'll also need all new seals
and gaskets plus the 5th gear bolt is one of those "always replace"
bolts (~$28). The rest is down to inspection. Some of the bearings are
bound to be bad. Specifically the small pinion shaft tapered roller
bearing is a prime suspect.
One note: if the large pinion shaft bearing needs to be replaced DO NOT
buy the bearing w/retainer plate from the dealer for ~$100. It's a
standard bearing and any idiot can install it in the existing retainer
plate using a hammer and punch.
Dan

Aaron Ness wrote:
> 
> In that case, what else should I do while I'm in there?  Is this the right
> time to be installing a bolt kit for the differential?  As I said, I need to
> keep the cost to a minimum.
> 
> Aaron
> '87 528e
> '82 Scirocco
> '70 Beetle
> '82 Kawasaki GPz550
> 
> > -----Original Message-----
> > From: owner-scirocco-l@scirocco.org
> > [mailto:owner-scirocco-l@scirocco.org]On Behalf Of Cheapass Ron
> > Sent: Tuesday, September 04, 2001 8:20 AM
> > To: aaron@makuta.com; 'scirocco'
> > Subject: Re: Replacing synchros
> >
> >
> > Replacing synchros is a full teardown/rebuild!  So you'll need all the
> > special tools that Mr. Bentley describes:
> > -driveaxle flange spring compressor
> > -circlip pliers for removing flanges
> > -triple square ??mm for removing 5th gear
> > -case separator (can make one out of angle iron)
> > -5th gear fork sleeve adjusting tool
> > -triple square for removing bearing retainer
> > -2-jaw gear puller, plus homemade extensions to reach 1st gear.
> > -propane torch, hot plate, or gas grill to remove/install certain
> > gears, etc.
> > -torque wrench >100ft-lbs iirc
> >
> > None of these tools are super special or expensive...make the case
> > separator and the extension arms to the gear puller, buy a set of
> > triple squares and the circlip pliers, use a steering wheel puller for
> > the flange spring compressor.
> >
> > Get lots of room and lay things out neatly.  Have fun!
> >
> > Ron
> >
> >
> > --- Aaron Ness <aaron@makuta.com> wrote:
> > > I'm getting ready to put the JH from my old '84 into my '82.
> > > However, both
> > > of my transmissions have worn synchros.  The FN in my '82 has a worn
> > > 3rd
> > > gear synchro, and the stock box from my '84 has worn
> > synchros in 2nd,
> > > 3rd,
> > > and 4th.
> > >
> > > If I were to just replace the synchros, would I need any special
> > > tools?  I
> > > need to keep this as cheap as I can, so I don't want to buy
> > the tools
> > > and do
> > > a full rebuild.  I just want the car to not grind when I shift after
> > > the
> > > swap is completed.
> > >
> > > Thanks...
> > > Aaron
> > > '87 528e
> > > '82 Scirocco
> > > '70 Beetle
> > > '82 Kawasaki GPz550
> > >
> > >
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> > >
> >
> >
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