20 Upgrades

egardless of the size of your engine or the shine on your , you can’t mate the two together with out a . The transmission and its BUGPACK 3560 Cadillac Ave. associated parts are as important as headlights at night. After all, they help Costa Mesa, CA 92626 R (714) 979-4990 transmit (hence the name) all of that ground-pounded power to the road. Follow- Fax (714) 979-3468 ing is a collection of parts that no Volkswagen should be without. 6 Gene Berg’s five-speed Conversion Kit includes lengthened main and pinion 1 SoCal Imports’ heavy duty Rhino trans- shafts, a new intermediate and shift hous- mission case comes directly from the OE ing, new five-speed selector rods, special manufacturer in Brazil. Extra gussetting 3 GB 667 keys for fifth gear, an extra thrust along the central spine of the casting washer for fifth, a 5mm fifth shift fork, fifth makes this one tough case. stop washer, special pinion and mainshaft nuts, and all needed nuts, bolts and wash- ers. Instructions are also included for the 1 dauntless do-it-yourselfer. This system has undergone several revisions since its first prototype in 1965, and stands as the premier five-speed kit on the market today. Gene berg Enterprises

4 The answer to noisy steel transaxle mounts, these durable mounts are made 6 in-house by BUGPACK from top quality urethane. They feature steel sleeves are grade five hardware, and the manufactur- 2 Complete IRS assemblies are also er claims they are virtually indestructable. available from SoCal. This is a complete assembly and includes the , dust boots, CV joints and all connecting hardware and clamps. SoCal also offers 4 refurbishing services for old, used IRS .

1725 N. Lime St. 2 Orange, CA 92865 (714) 998-7500 Fax (714) 998-7528

5 For serious off-road performance appli- 7 According to CB Performance, these cations, BUGPACK offers these heavy- Rhino transmission mounts effectively duty aluminum side plates. They replace double the strength of stock rubber the thrust side cover in order to prevent mounts. They are constructed from inject- flexing and damage under high horsepow- ed Isoform material for improved strength er and high side load conditions. Models and noise reduction. They are available to are available for swingaxle or IRS type fit both swingaxle and IRS configurations. assemblies on 1961 or later VW SoCal Imports . 8 Genuine VW 5.14:1 ring and pinion sets 6851 N. Paramount Blvd. Long Beach, CA 90805 (562) 633-4979 5 7 3 BUGPACK IRS differentials provide added strength needed to withstand the abuse doled out by high-horsepower engines. They eliminate the flex found in stock housings and provide for an extra pair of spider gears. They also allow infinite ring gear lash adjustment and do not affect or steering operation.

1 Courtesy of VW Trends FEBRUARY 2001 For Longer Life and Better Performance BY VWT STAFF restore highway cruising power and econo- my on vehicles that run tall aftermarket . Baja Bugs and off-road machines will What’s What in That Pile of Gears especially benefit from the lower 5.14:1 Volkswagen Transmission Glossary ratio. The kit is drilled and tapped for eight COMPILED BY ERIC DEBORD bolts and uses a keyed fourth gear. 002 differential—The type of differential used Nosecone—The front or first section of a VW in Three- and Five-rib Bus transmissions. transmission which contains the main shift 9 CB’s Super Duty Side Plates are 091 differential—Considered heavier and fork, sometimes called a “hockey stick” stronger than a 002, this differential is used in Operating Sleeves—Round rings with teeth on late style Type II transmissions from 1976. the inside and are what is shifted when you go 8 Anti Shocker—Device used to slow the travel into any forward gears. of the arm/pressure plate and to take One-Ringed Side Cover—A IRS transmission the shock off of a transmission in drag race- with one ring cast into the outside of the type starts. differential cover. Ball Bearings—Round bearings used in One-Sided Case—A IRS transmission case that various places in VW transmissions. only has one unboltable side cover. The early Cone Washer—Concave washer used on ones had two. mainshaft on early Type I transmissions and Output Flanges—See CV bells Three-rib Type II transmissions. Output Splines—The splines that the CV bells Coupler—Gear that couples the input shaft go onto. designed to keep your ring and pinion gear and mainshaft together in all VW transmis- Pinion—One half of a gearset. The “ring” gear properly meshed. They are thicker and sions. Also has external teeth to drive the is the other half. This is the final drive of a VW provide more strength than stock factory reverse idler shaft. transmission. side plates. The design includes an exter- CV bells—Output final drive flanges for Pinion Depth—Distance of the pinion into the nal O-ring to aid in preventing oil leaks at constant velocity joints ring gear in the final drive section. the location where the axle tube is bolted CV joint—Constant velocity joint (see sidebar) Pinion Shaft—Bottom shaft in a VW transmis- to the side plate. Super Duty Side plates Detent balls—Used to hold shift rails in sion. Contains the other half of the gearset, are available in two models to fit all 1961- position plus the pinion gear for the final drive. ’68 swingaxle transmissions and 1969-’77 End Gears—Sometimes called axle gears, Pressure Plate—Mechanism that applies force IRS Type I transmissions. these are the outer gears in the differential. to the clutch disc and flywheel to turn the CB Performance Five-Rib Transmission—Type II transmission input shaft of a transmission 1715 N. Farmersville Blvd. made from 1974-’75 Reduction Gearbox—Old-style Bus transmis- Flanges—See CV bells sion that further reduced the final drive by Four-Bolt Housing—Early type of transmis- having another set of gears next to the wheels. 9 sion case used in Type I transmissions. These outer sets of gears were in housings and Gear Carrier Housing—Sometimes called called “gear reduction” boxes. intermediate housing. This is the next section Reverse Gear Holder Setup—The fork that of a VW transmission behind the nose cone. supports the reverse idler gear. Gear Ratios—Driven gear divided by drive Rhino Case—Aftermarket braced Type I VW gear. Example—First gear is 10 tooth drive transmission case. and 38 driven. Divide 38 by 10 to equal 3.80 Ring and Pinion—Final drive set of gears used Gear Selector— The main shift fork some to lower the overall ratio of a transmission. times called a “hockey stick.” Six-Rib Transmission—Later style VW Type II Guide Tube—Tube for the throw-out bearing transmission from 1976 to ride on. Used in various VW transmissions Snap Rings—Used to keep bearings and gears Hydraulic Slave Cylinders—Clutch actuating from coming off of shafts cylinder used with a clutch master cylinder to Spider Gears—The small set of gears in differ Farmersville, CA 93223 release the clutch and pressure plate ential. They look somewhat like a spider, (800) 274-8337 Input Shaft— Splined shaft that the center of hence the name. Fax (559) 733-7967 the clutch disc rides on and is the first input Swingaxle—Early type of suspension and shaft of a VW transmission transaxle VW used. Until about 1969 10 California Imports offers a CV joint Input Shaft Coupler Gear—See Coupler Gear Three-Rib Transmission—Early style of Type rebuild kit for 1968- Intermediate Housing—See Gear Carrier II Bus transmission used from about 1968-’73 10 ’91 Type II and Housing Throwout Bearing—Bearing that pushes in 1969-’77 Type I IRS—Independent Rear Suspension—The the pressure plate. applications. Kits type of suspension and transmission VW used Transaxle—Term used for transmission and include all needed from 1970 up. Before that VW used a rear axle as one unit. hardware to exe- Swingaxle suspension and transmission. Two-Ringed Side Cover—IRS transmission cute the rebuild. Lubrication is supplied Mainshaft—Top shaft in a VW transmission. side cover that has two rings cast into it. separately. Contains half of the 1st-4th gearset. Two-Sided Case—VW transmission Type I Needle Bearings—Long small bearings used case that has two unboltable side covers. (all California Imports in various places in VW transmissions. swingaxles and IRS up to 1973).

2 Courtesy of VW Trends FEBRUARY 2001 Rebuilders and Suppliers

The best way to solve a wide variety of tranny rebuilds with special gear ratios, 1510 Grand Ave. super diffs and gussetted cases. Three San Marcos, CA 92069 transmission woes is to give it to a pro- different Type I sand transaxles are also (760) 744-9140 fessional transmission rebuilder or to available. Fax (760) 744-0967 2105 W. Cowles St. 1123 Fir Ave. purchase a rebuilt transmission. Long Beach, CA 90813 CALIFORNIA PACIFIC Blaine, WA 98230 (800) 508-7267 California Pacific offers transmission ser- Following is a list of competent (800) 313-3811 Fax (562) 435-8098 vices for almost any application. Custom Fax (877) 511-8111 rebuilders and suppliers that carry just jobs include reduced-rpm Freeway Fliers KUSTOM 1 WAREHOUSE and Pro Street transmissions. Custom about any type of transmission you may Kustom 1 Warehouse offers stock IRS or options and builds are available. 11 The Hurst-style swingaxle transmission rebuilds for 2040 Oceanside Blvd. need. shifter features Types I and III. They also offer Pro Oceanside, CA 92054 Street, Pro Comp and sand applications. (800) 231-1784 positive reverse MOFOCO All rebuilt and custom transaxles are Fax (760) 433-5527 lock out for slam- 11 MOFOCO refurbished transmissions available with or without stock axles. ming into second undergo an extensive road testing, total 1314 W. Collins Ave. CHIRCO disassembly and cleaning. MOFOCO will gear and a Orange, CA 92867 Chirco offers rebuilt transmissions for all rebuild all Beetle transmissions including (714) 997-9893 applications, including IRS, swingaxle loaded gate for swing axle, IRS and auto-stick applica- Fax (714) 289-0893 and automatic. Performance options are quicker shifts into tions, and all aircooled, watercooled and available, and transmissions can be third. Shifting into diesel Bus transmissions . MOTORWORKS assembled on a case by case basis. 102 W. Capitol Drive reverse is as sim- Rocky Mountain Motorworks offers 9101 E. 22nd St. Milwaukee, WI 53212 rebuilt transmissions with or without the Tucson, AZ 85710 ple as pulling up (800) 558-8955 axles. Transmissions are completely dis- (520) 722-1987 on the trigger and Fax (414) 963-2045 assembled and cleaned, and all worn or Fax (520) 298-4069 easing the handle damaged parts are replaced. Rebuilds TRANSMISSION WEST back as you would for most years for all Types are available. LONG ENTERPRISES Transmission West build VW transmis- 1003 Tamarac Pkwy. Long Enterprises has been remanufac- a stock assembly. sions to factory-spec and custom high Woodland Park, CO 80863 turing VW transaxles since the early 70s. performance, for off-road, sand and drag (800) 258-1996 They offer standard OE and high-perfor- 12 If you’re having a tough time shifting racing applications. According to the mance replacement parts for vintage company, customer satisfaction is their gears, it might be time to change your shift THE REAL SOURCE builders and high-performance enthusi- primary goal. The Real Source offers rebuilt swingaxle asts alike. coupler. Couplers are available in stock (310) 782-2413 transaxles for Beetles and Ghias 1961- 2475 Morse Road rubber or durable urethane, and are avail- ’68 and Type IIIs from 1964-’66. They Sebastopol, CA 95472 able for Bugs and Ghias from 1950-’79. STUFF TRANSAXLES offer rebuilt IRS transaxles for Beetles, (707) 829-1169 Stuff Transaxles is an internet-based Super Beetles and Ghias from 1969-’77. Fax (707) 823-5664 company specializing in rebuilt factory All rebuilt transmissions are thoroughly www.VWcyberStore.com and high-performance transaxles for vin- tested for quality. STRICTLY FOREIGN tage Types I, 181, II and III VWs. Two, One Mid America Place Strictly Foreign offers transaxle rebuild- three, four and five-speed transmissions P.O. Box 1248 ing services for any application, including are available, from strictly stock rebuilds Effingham, IL 62401 daily drivers, race and off-road vehi- to beefed up “gorillas.” The company (800) 588-2844 cles. According to the company, they 12 ships anywhere in the world. Fax (217) 347-2952 offer quality products at a fair price, as 3205 Production Ave., #I well as a 24-month warranty on all new Oceanside, CA 92054 RANCHO TRANSAXLES parts sold. (760) 721-8878 Rancho Performance Transaxles offers 405 Union Ave. #A Fax (760) 721-8188 transmissions for every VW application Grants Pass, OR 97527 www.bugtrans.com imaginable, ranging from bone stock (541) 476-1999 rebuilds to performance street, strip or Fax (541) 476-2131 FISHER BUGGIES off-road applications. Jobs are tailored to Fisher Buggies offers rebuilt stock customers’ specific needs, with numer- WEDDLE ENGINEERING swingaxle or IRS transmissions, Pro- ous performance options available. Weddle Engineering offers standard Street and Pro-Comp applications, and 1631 Placentia Ave. Unit G transmission rebuilding services, as well for strict racing applications, the Turbo Anaheim, CA 92806 as promoting several different high per- 13 The SCAT Drag Pro transaxle. Fisher also carries trans- (800) 304-8726 formance packages, including ring and missions for Type II applications from Fast shifter fea- (714) 680-3110 pinion sets, tall gearing kits and high- model years 1968-’79. tures an unbreak- strength replacement gears. 13 5126 S. Lois Ave. FAST GERMAN AUTO 700 Becknell Road, Unit A able forged shaft Tampa, FL 33611 Fast German Auto offers remanufactured Goleta, CA 93117 and heat treated (813) 837-6696 transmissions for practically every model (805) 696-9665 steel at all critical VW. The company can also customize Fax (805) 696-966 KCR VW TRANSMISSIONS transmissions according to customers’ wear surfaces. In KCR Transmissions specializes in build- needs. All transmissions are backed by a addition, it fea- ing standard shift VW transmissions. The 12-month, 12,000-mile warranty cover- tures positive company claims its low overhead allows ing parts and workmanship. them to sell top-quality rebuilds for less reverse lock out for 2911 S. Oak than many bigger companies. Custom Santa Ana, CA 92707 peace of mind and rebuilds are available, including sand, (888) 211-3334 a fully chrome plat- street or strip performance. Fax (714) 979-2974 ed shaft for great 9000 Arlington Ave. #108 Riverside, CA 92503 show looks. (909) 688-1904 Drag Fast shifters VW PARADISE Please call the company VW Paradise assembles transmissions are available for for all applications, including stock directly for more information Type I Sedans and TRANSFORM rebuilds, automatics, street or racing per- and a detailed list of services Transform offers rebuilds on numerous Type IIs 1961 and formance, or off road performance. VW transmissions. They specialize in and products provided. Paradise is one of the only shops to up. Type II sand performance and offer eight exclusively offer the new Mendeola different stages of Type II performance transmissions for racing applications.

3 Courtesy of VW Trends FEBRUARY 2001 SCAT Enterprises, Inc. Know What You’ve Got 1400 Kingsdale Ave. Redondo Beach, CA 90278 Volkswagen Transmission Codes (310) 370-5501 Code Engine Mate Final Drive Model Fax (310) 214-2285 AA 1200 4.375 From Number 0981810 AB 1300 4.375 Up to 1970 14 If you are contemplating removing or replac- AC 1500 4.125 On some 1300 from 1971 ing your VW’s transaxle, Volume Five AD 1200 4.375 Limited Slip Diff. (LSD) from the Bug Me Video series, 14 AE 1300 4.375 With LSD Transmission Replacement, is an invalu- AF 1500 4.125 LSD to 1970 able resource. The “Doctor,” Rick AG 1200 4.375 Used on Type 147 Higgens, shows you how to remove and AH 1500 4.125 IRS from 1969 reinstall the 1968 and earlier swingaxle 1600 4.125 1970-’71 tranny, as well as how to remove and AK 1500 3.875 Type 181 to 1970 reinstall the 1969 and later IRS 1600 3.875 Type 181 from 1971 transaxle, including CV joint inspection AL 1500 3.875 Type 181 with LSD to 1970 and maintenance. He even shows you 1600 3.875 Type 181 with IRS and LSD from 1971 how to renew leaky axle seals and how AM 1300 4.375 Sedan and Vert from 1971 to adapt 6-volt trannies to 12-volt fly- AN 1600 3.875 KG with IRS from 1971 wheels. AO 1300 3.875 KG from 1971 AP 1300 4.375 LSD from 1970-’71 AQ 1600 4.125 LSD from 1971-1972 Bug Me Video AR 1600 3.875 KG with LSD from 1971 P.O. Box 4176 AS 1600 3.875 Type I from 1973 N. Fort Myers, FL 33918 AT 1600 3.875 Type 1303 and Verts from 1973 (800) 662-0071 AU 1600 3.875 Type 1303 with LSD from 1973 BA 1300/1500 4.375 Auto-stick from 1969-’70 15 This is a replacement gear for BC 1300/1500 4.375 Auto-stick from 1969-’70 with LSD defective third and fourth Vanagon BE 1600 4.125 Auto-stick from 1971-’72 clutch gears. It was developed by 15 BF 1600 4.125 Auto-stick from 1971-’72 with LSD Long Enterprises to fix the cracking BG 1300 4.125 KG with auto-stick from 1971 problem on third and fourth gears BH 1300 4.125 KG with auto-stick from 1971 with LSD experienced by many Vanagon own- BJ 1300 4.375 Auto-stick from 1971 ers. BK 1300 4.375 Auto-stick from 1971 with LSD DA 1500/1600 4.125 Type III SA to 1968 Long Enterprises DB 1500/1600 4.125 Type III SA to 1968 with LSD 2475 Morse Road DC 1500/1600 4.125 Type III IRS from 1969 Sebastopol, CA 95472 DD 1500/1600 4.125 Type III IRS from 1969 with LSD (707) 829-1169 Fax (707) 823-5664

NOTES

4 Courtesy of VW Trends FEBRUARY 2001 the ball bearings, signs of lack of lubrication and excess heat. If they appear slightly marred, it is 18 Keeping a best to replace them and make sure your new joints have plenty of moly-type grease. Constant —Ryan Lee Price The most important thing to consider is Velocity the precision that’s needed to assem- ble one of these, A Closer Look at C.V. Joints especially consider- ERCO ing the heat and 9880 Indiana Ave. #26 Constant velocity joints (CV joints) are an abuse these com- Riverside, CA 92503 ponents must overlooked lot. They go about their business (909) 689-4430 endure. much like that of an oil pump or brake line, with Fax (909) 689-2640 little or no general maintenance, and it is high time they get the recognition they deserve. 19 Kustom 1 Warehouse offers transmis- 16 For a more judicious application of sion mounts for virtually any aircooled VW A CV joint is required to transmit all of the power on your spirited performance street application. Pictured here are replacement power generated by the engine and transmis- machine, Quaife torque biasing limited slip nose cone mounts, available for 1961-’77 sion through the axles and to the ground via the differentials are among the best available. Type Is, 1955-’72 Type IIs, and 1965-’73 wheels. As if that wasn’t stressing enough, they Differentials are available for most Type I Type IIIs. must perform their job while the suspension applications, including both swingaxle and moves up and down. To give you a good exam- ple of their beating, consider an off-road appli- 19 cation. As the car leaves the ground, the engine 16 sometimes surges in power until the car returns to the ground. At which time all of that torque is pushed through the CV joint and sometimes at radically acute angles. There are no small tasks, only small parts. The CV joint consists of four interlocking com- ponents: the outer shell, the cage, the ball bear- 20 Of course, Kustom 1 carries rear tranny ings and the center star. All of the inner parts ride IRS configurations. mounts as well. Rear mounts are available inside the outer shell. The cage secures the steel for 1964-’79 Type Is, 1967 Type IIs and ball bearings in the CV joint, while the center star 17 Several different replacement gear pack- 1964-’79 Type IIIs. holds the ball bearings to the outside of the cage. ages are available through ERCO. Shown is When you have your transmission out, it the company’s Phoenix brand 1131 Keyed Main Shaft kit. The kit includes a super doesn’t hurt to pull the CV boots off and have a heavy duty third gear and heavy duty 20 look at your joints. Inspect them for grooves in fourth, and is ideal for performance street the outer shell and a brownish discoloration of 17

or drag racing applications.

18 Diehl brand synchros are also available Kustom 1 Warehouse These are the components that make up a from ERCO. According to the company, 1314 W. Collins Ave. constant velocity joint: The outer shell houses this should be the first thing you replace Orange, CA 92867 the cage (top) the ball bearings and the center when rebuilding your transmission. Shown (714) 997-9893 star (right). are synchros for gears one through four. Fax (714) 289-0893

5 Courtesy of VW Trends FEBRUARY 2001 The Transaxle Zone Inside the Gobs of Gears and Grease

ho really knows what happens under the backseat of your Beetle or the rear Wbench or cargo area of your Bus? The engine runs, the lever moves from one gear to the other and the car goes forward and backward on command. But what happens when it does- Once the pinion assembly is in position, one side cover and bearings must be installed and a per- n’t or won’t or can’t? What then? For most of us, fectly flat magnetic plate is attached to the top of we’d simply pull the engine, drop the transaxle the pinion shaft to help determine its depth. Then, and run it down to the trusty Volkswagen trans- an extremely expensive tool is used to determine mission specialist of our choice (see sidebar on the correct pinion depth down to the hundredth Page XX if you don’t have one). They work their millimeter. magic, and it would come back to us (minus the grease and the broken parts) all shiny and new! The photo on the left illustrates the position that We’d put it back in and presto, we’re in business. first gear would be engaged on the pinion shaft, What’s inside of that black case is probably the and the photo on the right shows second gear most mysterious part of the whole car. engaged with the syncro operating sleeve. Many of you out there probably don’t have the tools, the patience or the volumes of knowledge it takes to rebuild one of these, and we don’t expect that you would. Any work on your trans- mission should be done by a professional, oth- erwise you’ll end up paying double: half to repair what you broke and the other half to fix what you should have fixed in the first place. Of course, this With the pinion depth established, the ring is by no means a comprehensive examination of gear can be installed and its backlash adjusted to help achieve a smooth opera- every component that is involved with the trans- This shows both sides of the final drive cov- tion. mission (that would take a book to do). Here is ers, which are commonly called side cov- just a peek inside and some clues as to what it ers, where the axle shafts originate. takes to put a transaxle together This is a .—Ryan Lee Price and Timothy N. Gavern common example of a swing- axle, full syncro, “tunnel style” transaxle.

Here is the completed assembly, with the The pinion gear is at the top with first gear through gear carrier, ready to be fitted into the fourth gear displayed in order from right to left. transaxle case. First gear and second gear move up and down on the pinion shaft. Third gear is splined, and fourth gear is held in place by a woodruff key, essential- ly making it integral to the pinion shaft. On the bot- tom is the main drive shaft in which first and sec- ond gear are integrally part of the shaft. At right are the third and fourth gears, which move up and down on the main drive shaft.

This is the ring gear (left) and the pinion shaft. Together they make up the ring and pinion, which is the With the gear carrier installed, the inner final drive set of gears On the left is the nosecone, or gearshift shift (hockey stick) and gearshift housing used to lower the housing, and on the right is the gear carrier, (nose cone) can be installed. overall ratio of a trans- which fits on the front of the transaxle case. mission.

6 Courtesy of VW Trends FEBRUARY 2001