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Date:         Mon, 14 Jan 2002 10:01:37 -0500
Reply-To:     "Chris Weddle (by way of Derek Drew <derekdrew@rcn.com>)"
              <info@2WEDDLE.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "Chris Weddle (by way of Derek Drew <derekdrew@rcn.com>)"
              <info@2WEDDLE.COM>
Subject:      More Weddle Wisdom--Gearbox rebuilding
Comments: To: Syncro@onelist.com
Content-Type: text/html; charset="us-ascii"

<html> <font size=3>Derek,<br> <br> Re: Front mainshaft bearing retaining key.<br> If the gear carrier housing (intermediate housing) is tight, the stock key will work fine. It's only purpose is to keep the outer race of the mainshaft bearing from spinning in the housing, which would cause the bore to wear very quickly. It is very rare for one of these keys to break unless a front mainshaft bearing explodes or the gear carrier housing becomes so worn that the mainshaft bearing is just plain sloppy (and this does happen sometimes).<br> <br> It is very common for the mainshaft bearing bore in the gear carrier housing to be loose after 140K miles or so. It should be a press fit, so if you try to push the bearing out of the housing with your thumbs and it moves (even a little bit), the housing is no good. Remember, when the trans warms up, the housing will be even looser!<br> <br> The proper fix for this problem is to machine out the bore and press in a 6061-T6 aluminum sleeve. Then bore the sleeve to the proper size so that the bearing fits like new. Actually, since the aluminum sleeve is tougher (more wear resistant) than the magnesium housing, this is a repair is actually &quot;better than new&quot;.<br> <br> While you are at it, it is a good idea to check the low gear housing where it contacts the front mainshaft bearing to make sure that the bearing hasn't beat its way into the mating surface. If the wear on the low gear housing is more than about .10mm (.004&quot;) deep, it is a good idea to replace it.<br> <br> And of course, if the retaining key has a step worn in it, go ahead and replace it with a new one (or a good used one). The part number for this key is 091-311-110A. We sell good used keys for 95 cents each. I don't know what the price of a new key is because we've never had to buy them. The key is the same as the one used in all 1976-1983 Bus and Vanagon transaxles, so we've always had a good supply of used ones with no discernable wear.<br> <br> Very Important: We sleeve the gear carrier housing in every one of our rebuilt transaxles, and I would recommend that all other builders do the same. This is a critical part of any quality rebuild. We sell sleeved 4wd gear carrier housings for $47.50 plus a $65.00 core charge. A properly sleeved housing should stay tight for another 140K miles (or until the next rebuild!).<br> <br> Regards,<br> <br> Chris Weddle<br> Weddle Industries<br> 700 Becknell Rd, Unit A<br> Goleta, CA 93117 USA<br> (805) 696-9665<br> Fax (805) 696-9667<br> info@2weddle.com<br> <br> <br> Daryl AA Transaxle Wisdom: <br> </font> <dl> <dd>The mainshaft brng retainer keys have been starting to fail fairly regularly in the last few years. <dd>I also have taken to making the keys for the mainshaft bearing from a larger stock. I also use some locktite when I install the bearing to try to make it more secure in the housing. I test fit a new bearing while the housing is hot (180deg) from the parts washer and in its most expanded state to see if the housing will be up to par. As these things get older with a pile of miles on them, we have been having to try to better some small points of the engineering as we go.<br> <br>

</dl>Daryl of AA Transaxle ----- Original Message ----- From: Jimmy Sanby (J) Sent: Thursday, December 27, 2001 11:13 PM To: SyncroSA@yahoogroups.com; Syncro@yahoogroups.com Subject: [Syncro] Syncro Gearbox&nbsp; Hi All<br> <br> I went to visit Syncroman yesterday who is rebuilding my box. Work is going well and I hope to have my vehicle back by the end of the weekend. The main problem was that the key that holds the main bearing in place on the drive shaft (input) wore and eventually broke in half. This the cased a piece of the outer casing of the bearing to break as well and and and...<br> <br> He showed me a couple of these keys that he had taken out of other boxes and they all seemed very worn, allowing lots of movement for the bearing. He makes his own key for replacement as the key supplied by the local VW agents are not to close enough tolerances (They still allow too much bearing movement). Can any of the other gearbox gurus out there give me some indication if they have also come across this problem of the key getting worn or breaking. Any ideas on the cause or preventative measures which other Syncro owners could look out for would also be appreciated.<br> <br> Jimmy Sanby '89 Syncro 15&quot; (Soon with decoupler) Cape Town, SA<br> <br> <br> <br> -----Original Message----- From: larsyncro [<a href="mailto:larsyncro@yahoo.co.uk" eudora="autourl">mailto:</a>larsyncro<a href="mailto:larsyncro@yahoo.co.uk" eudora="autourl">@yahoo.co.uk</a>] Sent: 27 December 2001 15:59 To: SyncroSA@yahoogroups.com Subject: [SyncroSA] re: T4 Ground clearance mods<br> <br> <br> <br> Hi Everyone Thanks to the guys that responded to my request.&nbsp; I will follow up as soon as I can extricate myself from a very busy Dec - Jan period. I do however have to respond to Gideons mail: &quot;But why don't you scour the country for an immaculate, low mileage, T3 Caravelle, put on 15&quot; alloys get a Steve's Auto Clinic stage 2 conversion,... Tint the windows, add curtains and you have a WonderWagen.&quot;<br> <br> Hi Gideon<br> <br> Thanks for the invitation, unfortunately I am allergic to wasserboxers! (Bad experiences way back ...) I currently have <tt>If you would like to modify your subscription settings (including unsubscribing), visit: <a href="http://groups.yahoo.com/group/Syncro" eudora="autourl">http://groups.yahoo.com/group/</a><a href="http://groups.yahoo.com/group/Syncro" eudora="autourl">Syncro</a> Please remember that rude or offensive language is not allowed on the Syncro list. Please try your best to resolve differences privately and keep them off the list.<br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> <br> Your use of Yahoo! Groups is subject to the Yahoo! Terms of Service &lt;<a href="http://docs.yahoo.com/info/terms/" eudora="autourl">http://docs.yahoo.com/info/terms/</a>&gt; .</tt> <br> <br> <br> _______________________________________________<br> Derek Drew&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; <br> CEO &amp; Co-Founder <br> <a href="http://www.consumersearch.com/" eudora="autourl">http://www.ConsumerSearch.com/</a> <br> New York, NY &amp; Washington DC<br> ===========================<br> &quot;Best Expert Review Site&quot; <br> for product reviews on the Internet <br> Jan. 2001, PC World Magazine<br> ==========================<br> derekdrew@rcn.com<br> 212-580-6486 <br> <br> Alternate numbers for the industrious phone caller that wants to try every avenue: 212-580-6486 (best), 917-848-6425 (cell); 202-966-7907 (Work), 212-580-4459 (Home), 202-966-0938 (Home), 978-359-8533 (fax [efax]), 212-269-3188 (New York Seaport office). <br> <br> <br> <br> <div>_______________________________________________</div> <div>Derek Drew&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; </div> <div>CEO &amp; Co-Founder </div> <div><a href="http://www.consumersearch.com/" EUDORA=AUTOURL>http://www.ConsumerSearch.com/</a> </div> <div>New York, NY &amp; Washington DC</div> <div>============================</div> <div>&nbsp;&nbsp;&nbsp; Best Consumer Advice Site&nbsp; </div> <div>&nbsp;&nbsp;&nbsp; PC World Magazine, Aug. 2001,</div> <div>============================</div> <div>&nbsp;&nbsp;&nbsp; ConsumerSearch is Best </div> <div>&nbsp;&nbsp;&nbsp; Newsweek, Nov. 5, 2001 </div> <div>============================</div> <div>derekdrew@rcn.com</div> <div>212-580-6486 </div> <br> Alternate numbers for the industrious phone caller that wants to try every avenue: 212-580-6486 (best), 917-848-6425 (cell); 202-966-7907 (Work), 212-580-4459 (Home), 202-966-0938 (Home), 978-359-8533 (fax [efax]). </html>


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