Date:         Fri, 11 Jun 1999 16:28:33 EDT
Reply-To:     Jwilli941@AOL.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Todd Hill <Jwilli941@AOL.COM>
Subject:      Re: Joe's Tranny questions...
Content-Type: text/plain; charset="us-ascii"

Joe asks....

<<..Can anyone quickly give me a tutorial on what the ABD/ACW
code trannys weak points are...>>>

Well, there really isn't any way to 'beef' them up to last longer
other than to take your time and use quality parts.  When in doubt,
throw it out!

As far as weak areas that were 'designed' into them I can only
think of a couple off hand:

Crack prone 3rd/4th hub
If 4.83 ring and pinion then usually bad

Easy to fix during rebuilds.

Replace old style with new style 3rd/4th hub,  replace 3rd and
4th mainshaft halves of gearsets if excessively worn, replace
mainshaft ball bearing, check mainshaft ball bearing bore-if loose
then replace with sleeved housing, check front pinion shaft roller
bearing outer race for pitting at the 4-5 o'clock position, new
moly coated synchros,  replace 1st and 2nd pinion shaft idler
gears if excessively worn, check 1st/2nd slider, replace pinion
bearing (NOTE- I have been informed that the current production
run of the 091 tapered roller pinion bearings is out.  Unknown
when FAG will make another production run) , replace ball sleeves
on forward gears fork arms, replace gear carrier housing if shift
rod bores are cracked, replace early style 1st/2nd gear relay lever
with new style, check pinion bearing bore in transaxle maincase
and replace said case if excessively worn,  replace differential
final drive tapered roller bearings, new clutch throw out bearing
arm, surface the nosecone mating surface,  replace pitted (usually)
6 tooth pinion 4.83 set with 7 tooth pinion 4.86 ring and pinion,
new seals, gaskets, circlips, and so on.

This is why I sell them for what I do!

-Todd Hill
 VolksWerks Transaxles
 Olympia, WA
 360-412-0948

PS- I have a rebuilt 091-1 ready to go if needed.