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transmission recap (long)

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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.=20

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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charset=3Diso-8859-1">
<META content=3D"MSHTML 6.00.2715.400" name=3DGENERATOR>
<STYLE></STYLE>
</HEAD>
<BODY bgColor=3D#ffffff>
<DIV><FONT face=3DArial size=3D2>This is long but hoped to give info to =
others who=20
aren't familiar with this information.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>Thanks to the expert help of Cheapass =
Ron I got my=20
AGB tranny rebuilt last Monday but it was an all day job. I think I =
slowed Ron=20
down. My troubles were hard shifting but no grinding noise and no =
slipping out=20
of gear.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>As we opened the tranny we found the =
gears,=20
bearings, and synchros in good condition. However when we looked at the=20
differential we discovered that I was deep into the SMS syndrome. Two =
rivet=20
heads had already come off. We found one and I guess the other got =
ground up. We=20
also discovered that one gear on the ring gear had been broken off. =
Pushrod=20
looked ok, just a little worn. The biggest concern was that the SMS had =
ground=20
the case around the pinion gear race and had made cuts into the case =
around the=20
differential. As it looked I was not far away from a total destruction =
of my=20
tranny. Luckily I had already planned on repairing the SMS and ordered a =
bolt=20
kit from Peter and a Peloquin&nbsp; 80% LSD kit. Oh, we also found one =
of the=20
factory slip rings in the differential was broken. There was all kinds =
of metal=20
in the case requiring a good cleaning. The magnet, which I had no idea =
the=20
tranny had, was covered with metal fragments. The metal was so pervasive =
that=20
the detent dogs on the fifth gear (we didn't check the others) were =
filled with=20
metal.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>I should also note that I had already =
found that=20
the rear tranny mount was sheared in two and had replaced it. After =
removing the=20
tranny I found the driver's side mount was cracked. I've not had time to =
check=20
the right side yet but I pre-purchased one figuring it too is bad. My =
local=20
machine shop pressed in the left mount for the transaxle for $16.00. The =
mounts=20
came from Potterman.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>We went ahead and replaced the 2,3,4 =
sychros and of=20
course the bolt kit and LSD kit. The Peloquin LSD kit is one nice piece =
of work.=20
Very well done with excellent instructions and definately a better job =
than VW=20
did.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>I've yet to get the tranny put in but =
am looking=20
forward to sweet running shifts. I've no idea when the rivets first went =
or how=20
long I drove it with two off. But much longer and I'd have had a hole in =
the=20
case.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>I have already replaced the shifter =
bushings. New=20
motor mounts should help. The transmission work is doable in one's =
garage but=20
there are homemade speciality tools needed and a couple of tricks. If I =
had=20
tried to do this without Ron's help I'd have probably given up. The two =
main=20
tools Ron had made were one to split the case consisted of two pieces of =
angle=20
iron. On drilled and tapped for a bolt that pushes against the other =
angle iron=20
laying&nbsp; on the main shaft bolt. Two other holes were drilled to run =
two=20
fifth gear housing bolts through as guides. </FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>The other tool is a gear puller with =
longer pieces=20
made so as to reach all the way to the end of the main shaft gears. The =
hooks=20
are put under the gears and the pulling bolt is placed against the =
mainshaft=20
bolt hole.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>Other tools are pretty =
standard.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>Some things I've learned about hard=20
shifting.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2></FONT>&nbsp;</DIV>
<DIV><FONT face=3DArial size=3D2>Check all the motor mounts and replace =
as=20
necessary.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2>Replace the shift bushing, ball and =
align the=20
shifter.</FONT></DIV>
<DIV><FONT face=3DArial size=3D2>If the transmission hasn't been rebuilt =
then do it=20
as soon as possible. I almost lost my second tranny to=20
SMS.</FONT></DIV></BODY></HTML>

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