Date:         Mon, 8 Jun 1998 16:28:01 EDT
Reply-To:     Jwilli941@AOL.COM
Sender:       Vanagon Mailing List <Vanagon@vanagon.com>
From:         Todd Hill <Jwilli941@AOL.COM>
Subject:      Re: Stuck in gear-reply
Comments: To: vw4x4@fyi.net
Comments: cc: vanagon@VANAGON.COM
Content-type: text/plain; charset=US-ASCII

In a message dated 98-06-07 23:59:43 EDT, Eric wrote

<<  DOes anyone know what cracks these?>>

The torque load and weight of the Van are likely
culprits.  The orginal design had square cut slots
in the clutch hubs for the floating 'dogs'.  This was
just fine for less HP and weight but the Vanagon
stressed the design.  The new style hubs have an
oval cut out to relieve any right angles that can lead
to this type of cracking.  Seems to be working so far

 <<What can be done to prevent the cracking?>>

Nada, they'll crack no matter what.  Its just a matter
of time before they let go.  Usually the driver will find
that it becomes difficult to shift into 3rd or 4th and it
gradually gets worse.  Eventually, the hub cracks fully
round and the slider is jammed to one side or the other
and you're stuck.

<< Is there any way to tell from the outside if a
 Syncro trans. Has been updated  with the new hubs? >>

Nope, its an internal part that isn't visible from the
outside.  If the trans has been rebuilt then they should
have installed the new style hub as a matter of course-
at least I do on my rebuilds.  Because of the expense
of the hub (around $275) some cheeseball outfits may
not replace the hub if they do not see any cracking
but it is only delaying the inevitable and will force the
owner to pay twice for repairing a fault that should have
been taken care of the first time.

Todd Hill
VolksWerks Transaxles
Olympia, WA