http://vanagonsyncroproject-herman.blogspot.com/). Here Herman shows his transmission solution, but I'm reluctant to tear open the transmission again. Fascinating approaches! Excellent reading.
Frank Grunthaner
-----Original Message-----
From: Don Hanson <dhanson928@gmail.com>
To: TDI-conversion@yahoogroups.com
Sent: Mon, Jan 4, 2010 7:11 am
Subject: Re: [TDI-conversion] Re: Conversion? JETTA ENGINE?? Now Some TDi Comments (Shortened Version)
Scott, Frank
Here are a couple of ideas on helping a tranny stay alive when you are feeding it big torque.
Keeping the internal temp down seems critical. A positive flow transmission cooling system is beneficial. A good source for the components and plumbing parts to fabricate one might be here:
http://www.batinc.net/porsche.htm
Go back to the BAT homepage for a huge selection of hydraulic fittings, hoses, etc. No personal affiliation with BAT other than I used them when fabricating a system for my big torque stroker V8 Porsche racecar transmission.
With some careful planning you'll be able to safely keep the operating temps of your trans axle within acceptable limits. I was told the repeated failures I saw, until I addressed the problem, were caused partially because, as the trans axle gained excessive heat, the internal tolerances changed, generating further heat ...creating a bad situation.. I say you must use "careful planning" for a tans axle cooling system..It should be designed and executed so that if any of the extra components (hoses, pumps, wiring, sensors, switches, etc) should fail, the transmission will revert to it's 'un-cooled' state, rather than become unlubricated..
I was able to configure the system on my 928 trans using the filler and drain openings. Seems like this might be a viable approach for most trannys and a way to work up a cooler system without extensive machine work on the transmission cases..
You might also, should you have your tranny apart, consider having the internals cryogenic-ally treated. I am told this is similar in results to bead blasting (it is supposed to reduce 'internal stress' in the part that is 'super-cooled') and the process is fairly rea$onable and quick. I was told all the NASCAR teams do this routinely, so on my final transmission ( before I ran out of spendable income and ceased racing my big sporty car) I had my internals cryogenic ally treated. With good cooling and perhaps that cryo-treatment, I was able to race a full season without another failure of my gears..Cryogenics might be BS, but the cost was comparatively little in my racing budget so I did it and I'd do it again for a high-torque application.
Running a Vanagon at sustained higher speeds against a headwind/uphill or with a big load...in combo with extra power..it will create more heat in the gears...If and when the internals become excessively hot the various components expand, often at different rates, causing even more friction, which in turn causes even more heat...Better to spend a few hundred on keeping things cool, if you are running a power train that might push the design limits of your tranny.
Don Hanson
Mon, Jan 4, 2010 at 3:42 AM, Scott Greiner <greines@yahoo.com> wrote:
Frank,
Thank you for your time and thorough details. If you are ever in the Phx, AZ area, let me know! Dinner and Drinks are on me.
Scott Greiner
Mesa, AZ
1982 Diesel Westy-With a 1997 Jetta AHU 1.9 TDI
DZ Transaxle Re-Built with a 3rd 1.14, 4th .70 & a 4.57 R&P by AZTransaxles in Phx, AZ - Thanks Bill
Engine Left Mount - "To clear the Turbo", Viton Fuel Line Kit & VS Sensor, etc from GreaseWorks- Thanks Justin; great website!!
R&R of 1997 Jetta TDI Donor Car's Engine, ECU, Wire harness, intercooler, rebuilting the turbo, in to my 82 Diesel Westy- Thanks Paul my friend & neighbor.
Exhaust System - Stock 1997 Jetta's Header pipe with 4" high flow muffler form local shop.
Misc parts, thanks BAP, PartsPlace Inc., Carl's VW Speed Shop, Autohaus
South Bend Clutch Inc - Thanks Andy for the 228mm Clutch Plate
Air Cleaner - K&N from Pep-Boys
Intercooler Piping Fabrication by my friend Mark-Thanks!
Lots of help from the awesome members of this forum-Thanks!
A whole lot of Vanagon Websites - Thanks for Shaing!
My Cuzin Carl for giving me this broken down VW Vanagon.
My Wife for putting up with me though all this. Thanks Margaret
My friend Zac for starting me on Bio-Diesel.
Adding a 1987 Vanagon Instrument Cluster "bought off E-Bay" for Cruise Control-Soon!
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