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20 Transaxle Upgrades 20 Transaxle Upgrades egardless of the size of your engine or the shine on your wheels, you can’t mate the two together with out a transmission. 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 axle assemblies are also er claims they are virtually indestructable. available from SoCal. This is a complete assembly and includes the drive shaft, dust boots, CV joints and all connecting hardware and clamps. SoCal also offers 4 refurbishing services for old, used IRS axles. 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 transaxles. 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 steering or steering brake 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 tires. 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 clutch 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.
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