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transmission recap (long)
Ehhh...here's what's going on: Al's bringing a tranny with a weird
problem, Saturday the tech procedure will be to simply tear it down and
determine what's wrong.
I'll be delivering a rebuilt one to Patrick at Cincy, and may have to
do one for Big Mac by then also.
Sunday is autox day!
If you leave it with me, I can do everthing after Cincy, and ship it to
you. Quaife install is no sweat, but it takes time to set the preload
correctly. Don't want the pressure at Cincy!
Lemme know...
Ron
--- Night Shadow <soltwede@privateI.com> wrote:
>
> So Ron...you up for a quaife install/rebuild of a 2H with .75 5th at
> Cincy?
>
> Eric
> (thinkin he might have to drag *3* trannies to cincy...)
>
>
>
> On Sat, 11 May 2002, Ron Pieper wrote:
>
> > 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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> >
>
> --
> Eric
> Northglenn, CO
>
> 76 Honda CB400F Super Sport
> 80 Scirocco (Parts car again, no more DD duty)
> 81 Scirocco S (2.0 16v swap and complete restoration in progress)
> 81 Rabbit Truck LX Diesel (THE NEW RIDE)
> 91 Cabriolet (2.0 Crossflow 8v swap and mechanical rebuild in
> progress)
> 00 Golf GL TDI (Katy is driving this for now)
>
> "For Aquarians, the physics of loopholes is a perfectly valid
> science."
> -Kelli Fox
>
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