20 Transaxle Upgrades

egardless of the size of your engine or the shine on your wheels, you cant mate the two together with out a transmission. The transmission and its associated parts are as important as headlights at night. After all, they help
BUGPACK 3560 Cadillac Ave. Costa Mesa, CA 92626 (714) 979-4990 Fax (714) 979-Gene Bergs five-speed Conversion Kit includes lengthened main and pinion shafts, a new intermediate and shift housing, new five-speed selector rods, special GB 667 keys for fifth gear, an extra thrust washer for fifth, a 5mm fifth shift fork, fifth stop washer, special pinion and mainshaft nuts, and all needed nuts, bolts and washers. Instructions are also included for the 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
transmit (hence the name) all of that ground-pounded power to the road. Following is a collection of parts that no Volkswagen should be without.
1 SoCal Imports heavy duty Rhino transmission case comes directly from the OE manufacturer in Brazil. Extra gussetting along the central spine of the casting makes this one tough case.
2 Complete IRS axle assemblies are also 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 refurbishing services for old, used IRS axles.
4 The answer to noisy steel transaxle mounts, these durable mounts are made in-house by BUGPACK from top quality urethane. They feature steel sleeves are grade five hardware, and the manufacturer claims they are virtually indestructable.
1725 N. Lime St. Orange, CA 92865 (714) 998-7500 Fax (714) 998-For serious off-road performance applications, BUGPACK offers these heavyduty aluminum side plates. They replace the thrust side cover in order to prevent flexing and damage under high horsepower and high side load conditions. Models are available for swingaxle or IRS type assemblies on 1961 or later VW transaxles. 7 According to CB Performance, these Rhino transmission mounts effectively double the strength of stock rubber mounts. They are constructed from injected Isoform material for improved strength and noise reduction. They are available to fit both swingaxle and IRS configurations. 8 Genuine VW 5.14:1 ring and pinion sets
SoCal Imports 6851 N. Paramount Blvd. Long Beach, CA 90805 (562) 633-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.

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VW Trends

FEBRUARY 2001

For Longer Life and Better Performance

BY VWT STAFF

restore highway cruising power and economy on vehicles that run tall aftermarket tires. Baja Bugs and off-road machines will especially benefit from the lower 5.14:1 ratio. The kit is drilled and tapped for eight bolts and uses a keyed fourth gear. 9 CBs Super Duty Side Plates are
Whats What in That Pile of Gears
Volkswagen Transmission Glossary

002 differentialThe type of differential used in Three- and Five-rib Bus transmissions. 091 differentialConsidered heavier and stronger than a 002, this differential is used in late style Type II transmissions from 1976. Anti ShockerDevice used to slow the travel of the clutch arm/pressure plate and to take the shock off of a transmission in drag racetype starts. Ball BearingsRound bearings used in various places in VW transmissions. Cone WasherConcave washer used on mainshaft on early Type I transmissions and Three-rib Type II transmissions. CouplerGear that couples the input shaft and mainshaft together in all VW transmissions. Also has external teeth to drive the reverse idler shaft. CV bellsOutput final drive flanges for constant velocity joints CV jointConstant velocity joint (see sidebar) Detent ballsUsed to hold shift rails in position End GearsSometimes called axle gears, these are the outer gears in the differential. Five-Rib TransmissionType II transmission made from 1974-75 FlangesSee CV bells Four-Bolt HousingEarly type of transmission case used in Type I transmissions. Gear Carrier HousingSometimes called intermediate housing. This is the next section of a VW transmission behind the nose cone. Gear RatiosDriven gear divided by drive gear. ExampleFirst gear is 10 tooth drive and 38 driven. Divide 38 by 10 to equal 3.80 Gear Selector The main shift fork some times called a hockey stick. Guide TubeTube for the throw-out bearing to ride on. Used in various VW transmissions Hydraulic Slave CylindersClutch actuating cylinder used with a clutch master cylinder to release the clutch and pressure plate Input Shaft Splined shaft that the center of the clutch disc rides on and is the first input shaft of a VW transmission Input Shaft Coupler GearSee Coupler Gear Intermediate HousingSee Gear Carrier Housing IRSIndependent Rear SuspensionThe type of suspension and transmission VW used from 1970 up. Before that VW used a Swingaxle suspension and transmission. MainshaftTop shaft in a VW transmission. Contains half of the 1st-4th gearset. Needle BearingsLong small bearings used in various places in VW transmissions.

COMPILED BY ERIC DEBORD

designed to keep your ring and pinion gear properly meshed. They are thicker and provide more strength than stock factory side plates. The design includes an external O-ring to aid in preventing oil leaks at the location where the axle tube is bolted to the side plate. Super Duty Side plates are available in two models to fit all 196168 swingaxle transmissions and 1969-77 IRS Type I transmissions. CB Performance 1715 N. Farmersville Blvd.
Farmersville, CA 93223 (800) 274-8337 Fax (559) 733-California Imports offers a CV joint rebuild kit for 196891 Type II and 1969-77 Type I applications. Kits include all needed hardware to execute the rebuild. Lubrication is supplied separately. California Imports

NoseconeThe front or first section of a VW transmission which contains the main shift fork, sometimes called a hockey stick Operating SleevesRound rings with teeth on the inside and are what is shifted when you go into any forward gears. One-Ringed Side CoverA IRS transmission with one ring cast into the outside of the differential cover. One-Sided CaseA IRS transmission case that only has one unboltable side cover. The early ones had two. Output FlangesSee CV bells Output SplinesThe splines that the CV bells go onto. PinionOne half of a gearset. The ring gear is the other half. This is the final drive of a VW transmission. Pinion DepthDistance of the pinion into the ring gear in the final drive section. Pinion ShaftBottom shaft in a VW transmission. Contains the other half of the gearset, plus the pinion gear for the final drive. Pressure PlateMechanism that applies force to the clutch disc and flywheel to turn the input shaft of a transmission Reduction GearboxOld-style Bus transmission that further reduced the final drive by having another set of gears next to the wheels. These outer sets of gears were in housings and called gear reduction boxes. Reverse Gear Holder SetupThe fork that supports the reverse idler gear. Rhino CaseAftermarket braced Type I VW transmission case. Ring and PinionFinal drive set of gears used to lower the overall ratio of a transmission. Six-Rib TransmissionLater style VW Type II transmission from 1976 Snap RingsUsed to keep bearings and gears from coming off of shafts Spider GearsThe small set of gears in differ ential. They look somewhat like a spider, hence the name. SwingaxleEarly type of suspension and transaxle VW used. Until about 1969 Three-Rib TransmissionEarly style of Type II Bus transmission used from about 1968-73 Throwout BearingBearing that pushes in the pressure plate. TransaxleTerm used for transmission and rear axle as one unit. Two-Ringed Side CoverIRS transmission side cover that has two rings cast into it. Two-Sided CaseVW transmission Type I case that has two unboltable side covers. (all swingaxles and IRS up to 1973).

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Rebuilders and Suppliers
The best way to solve a wide variety of transmission woes is to give it to a professional transmission rebuilder or to purchase a rebuilt transmission. Following is a list of competent rebuilders and suppliers that carry just about any type of transmission you may need. MOFOCO MOFOCO refurbished transmissions undergo an extensive road testing, total disassembly and cleaning. MOFOCO will rebuild all Beetle transmissions including swing axle, IRS and auto-stick applications, and all aircooled, watercooled and diesel Bus transmissions. 102 W. Capitol Drive Milwaukee, WI 53212 (800) 558-8955 Fax (414) 963-2045 TRANSMISSION WEST Transmission West build VW transmissions to factory-spec and custom high performance, for off-road, sand and drag racing applications. According to the company, customer satisfaction is their primary goal. (310) 782-2413 STUFF TRANSAXLES Stuff Transaxles is an internet-based company specializing in rebuilt factory and high-performance transaxles for vintage Types I, 181, II and III VWs. Two, three, four and five-speed transmissions are available, from strictly stock rebuilds to beefed up gorillas. The company ships anywhere in the world. 3205 Production Ave., #I Oceanside, CA 92054 (760) 721-8878 Fax (760) 721-8188 www.bugtrans.com FISHER BUGGIES Fisher Buggies offers rebuilt stock swingaxle or IRS transmissions, ProStreet and Pro-Comp applications, and for strict racing applications, the Turbo Pro transaxle. Fisher also carries transmissions for Type II applications from model years 1968-79. 5126 S. Lois Ave. Tampa, FL 33611 (813) 837-6696 KCR VWTRANSMISSIONS KCR Transmissions specializes in building standard shift VW transmissions. The company claims its low overhead allows them to sell top-quality rebuilds for less than many bigger companies. Custom rebuilds are available, including sand, street or strip performance. 9000 Arlington Ave. #108 Riverside, CA 92503 (909) 688-1904 tranny rebuilds with special gear ratios, super diffs and gussetted cases. Three different Type I sand transaxles are also available. 2105 W. Cowles St. Long Beach, CA 90813 (800) 508-7267 Fax (562) 435-8098 KUSTOM 1 WAREHOUSE Kustom 1 Warehouse offers stock IRS or swingaxle transmission rebuilds for Types I and III. They also offer Pro Street, Pro Comp and sand applications. All rebuilt and custom transaxles are available with or without stock axles. 1314 W. Collins Ave. Orange, CA 92867 (714) 997-9893 Fax (714) 289-0893 MOTORWORKS Rocky Mountain Motorworks offers rebuilt transmissions with or without the axles. Transmissions are completely disassembled and cleaned, and all worn or damaged parts are replaced. Rebuilds for most years for all Types are available. 1003 Tamarac Pkwy. Woodland Park, CO 80863 (800) 258-1996 THE REAL SOURCE The Real Source offers rebuilt swingaxle transaxles for Beetles and Ghias 196168 and Type IIIs from 1964-66. They offer rebuilt IRS transaxles for Beetles, Super Beetles and Ghias from 1969-77. All rebuilt transmissions are thoroughly tested for quality. One Mid America Place P.O. Box 1248 Effingham, IL 62401 (800) 588-2844 Fax (217) 347-2952 RANCHO TRANSAXLES Rancho Performance Transaxles offers transmissions for every VW application imaginable, ranging from bone stock rebuilds to performance street, strip or off-road applications. Jobs are tailored to customers specific needs, with numerous performance options available. 1631 Placentia Ave. Unit G Anaheim, CA 92806 (800) 304-8726 (714) 680-3110 FAST GERMAN AUTO Fast German Auto offers remanufactured transmissions for practically every model VW. The company can also customize transmissions according to customers needs. All transmissions are backed by a 12-month, 12,000-mile warranty covering parts and workmanship. 2911 S. Oak Santa Ana, CA 92707 (888) 211-3334 Fax (714) 979-Grand Ave. San Marcos, CA 92069 (760) 744-9140 Fax (760) 744-0967 CALIFORNIA PACIFIC California Pacific offers transmission services for almost any application. Custom jobs include reduced-rpm Freeway Fliers and Pro Street transmissions. Custom options and builds are available. 2040 Oceanside Blvd. Oceanside, CA 92054 (800) 231-1784 Fax (760) 433-5527 CHIRCO Chirco offers rebuilt transmissions for all applications, including IRS, swingaxle and automatic. Performance options are available, and transmissions can be assembled on a case by case basis. 9101 E. 22nd St. Tucson, AZ 85710 (520) 722-1987 Fax (520) 298-4069 LONG ENTERPRISES Long Enterprises has been remanufacturing VW transaxles since the early 70s. They offer standard OE and high-performance replacement parts for vintage builders and high-performance enthusiasts alike. 2475 Morse Road Sebastopol, CA 95472 (707) 829-1169 Fax (707) 823-5664 STRICTLY FOREIGN Strictly Foreign offers transaxle rebuilding services for any application, including daily drivers, race cars and off-road vehicles. According to the company, they offer quality products at a fair price, as well as a 24-month warranty on all new parts sold. 405 Union Ave. #A Grants Pass, OR 97527 (541) 476-1999 Fax (541) 476-2131 WEDDLE ENGINEERING Weddle Engineering offers standard transmission rebuilding services, as well as promoting several different high performance packages, including ring and pinion sets, tall gearing kits and highstrength replacement gears. 700 Becknell Road, Unit A Goleta, CA 93117 (805) 696-9665 Fax (805) 696-966

1123 Fir Ave. Blaine, WA 98230 (800) 313-3811 Fax (877) 511-The Hurst-style shifter features positive reverse lock out for slamming into second gear and a spring loaded gate for quicker shifts into third. Shifting into reverse is as simple as pulling up on the trigger and easing the handle back as you would a stock assembly.
12 If youre having a tough time shifting gears, it might be time to change your shift coupler. Couplers are available in stock rubber or durable urethane, and are available for Bugs and Ghias from 1950-79. www.VWcyberStore.com
TRANSFORM Transform offers rebuilds on numerous VW transmissions. They specialize in Type II sand performance and offer eight different stages of Type II performance
VW PARADISE VW Paradise assembles transmissions for all applications, including stock rebuilds, automatics, street or racing performance, or off road performance. Paradise is one of the only shops to exclusively offer the new Mendeola transmissions for racing applications.
Please call the company directly for more information and a detailed list of services and products provided.
13 The SCAT Drag Fast shifter features an unbreakable forged shaft and heat treated steel at all critical wear surfaces. In addition, it features positive reverse lock out for peace of mind and a fully chrome plated shaft for great show car looks. Drag Fast shifters are available for Type I Sedans and Type IIs 1961 and up.

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SCAT Enterprises, Inc. 1400 Kingsdale Ave. Redondo Beach, CA 90278 (310) 370-5501 Fax (310) 214-If you are contemplating removing or replacing your VWs transaxle, Volume Five from the Bug Me Video series, Transmission Replacement, is an invaluable resource. The Doctor, Rick Higgens, shows you how to remove and reinstall the 1968 and earlier swingaxle tranny, as well as how to remove and reinstall the 1969 and later IRS transaxle, including CV joint inspection and maintenance. He even shows you how to renew leaky axle seals and how to adapt 6-volt trannies to 12-volt flywheels. Bug Me Video P.O. Box 4176 N. Fort Myers, FL 33918 (800) 662-This is a replacement gear for defective third and fourth Vanagon clutch gears. It was developed by Long Enterprises to fix the cracking problem on third and fourth gears experienced by many Vanagon owners. Long Enterprises 2475 Morse Road Sebastopol, CA 95472 (707) 829-1169 Fax (707) 823-5664

Know What Youve Got

Volkswagen Transmission Codes
Code AA AB AC AD AE AF AG AH AK AL AM AN AO AP AQ AR AS AT AU BA BC BE BF BG BH BJ BK DA DB DC DD Engine Mate 1200 4.4.4.4.4.4.4.4.4.3.3.3.3.4.3.3.4.4.3.3.3.3.875 1300/15004.375 1300/15004.4.4.4.4.4.4.375 1500/16004.125 1500/16004.125 1500/16004.125 1500/16004.125
Final Drive Model From Chassis Number 0981810 Up to 1970 On some 1300 from 1971 Limited Slip Diff. (LSD) With LSD LSD to 1970 Used on Type 147 IRS from 1969 1970-71 Type 181 to 1970 Type 181 from 1971 Type 181 with LSD to 1970 Type 181 with IRS and LSD from 1971 Sedan and Vert from 1971 KG with IRS from 1971 KG from 1971 LSD from 1970-71 LSD from 1971-1972 KG with LSD from 1971 Type I from 1973 Type 1303 and Verts from 1973 Type 1303 with LSD from 1973 Auto-stick from 1969-70 Auto-stick from 1969-70 with LSD Auto-stick from 1971-72 Auto-stick from 1971-72 with LSD KG with auto-stick from 1971 KG with auto-stick from 1971 with LSD Auto-stick from 1971 Auto-stick from 1971 with LSD Type III SA to 1968 Type III SA to 1968 with LSD Type III IRS from 1969 Type III IRS from 1969 with LSD

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Keeping a Constant Velocity
A Closer Look at C.V. Joints
Constant velocity joints (CV joints) are an overlooked lot. They go about their business much like that of an oil pump or brake line, with little or no general maintenance, and it is high time they get the recognition they deserve. A CV joint is required to transmit all of the power generated by the engine and transmission through the axles and to the ground via the wheels. As if that wasnt stressing enough, they must perform their job while the suspension moves up and down. To give you a good example of their beating, consider an off-road application. As the car leaves the ground, the engine 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 components: the outer shell, the cage, the ball bearings and the center star. All of the inner parts ride inside the outer shell. The cage secures the steel ball bearings in the CV joint, while the center star holds the ball bearings to the outside of the cage. When you have your transmission out, it doesnt hurt to pull the CV boots off and have a look at your joints. Inspect them for grooves in the outer shell and a brownish discoloration of
the ball bearings, signs of lack of lubrication and excess heat. If they appear slightly marred, it is best to replace them and make sure your new joints have plenty of moly-type grease. Ryan Lee Price
The most important thing to consider is the precision thats needed to assemble one of these, especially considering the heat and abuse these components must endure.
ERCO 9880 Indiana Ave. #26 Riverside, CA 92503 (909) 689-4430 Fax (909) 689-Kustom 1 Warehouse offers transmission mounts for virtually any aircooled VW application. Pictured here are replacement nose cone mounts, available for 1961-77 Type Is, 1955-72 Type IIs, and 1965-73 Type IIIs.
16 For a more judicious application of power on your spirited performance street machine, Quaife torque biasing limited slip differentials are among the best available. Differentials are available for most Type I applications, including both swingaxle and
IRS configurations. 17 Several different replacement gear packages are available through ERCO. Shown is the companys Phoenix brand 1131 Keyed Main Shaft kit. The kit includes a super heavy duty third gear and heavy duty fourth, and is ideal for performance street
20 Of course, Kustom 1 carries rear tranny mounts as well. Rear mounts are available for 1964-79 Type Is, 1967 Type IIs and 1964-79 Type IIIs.

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

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The Transaxle Zone
Inside the Gobs of Gears and Grease
ho really knows what happens under the backseat of your Beetle or the rear bench 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 doesnt or wont or cant? What then? For most of us, wed simply pull the engine, drop the transaxle and run it down to the trusty Volkswagen transmission specialist of our choice (see sidebar on Page XX if you dont have one). They work their magic, and it would come back to us (minus the grease and the broken parts) all shiny and new! Wed put it back in and presto, were in business. Whats inside of that black case is probably the most mysterious part of the whole car. Many of you out there probably dont have the tools, the patience or the volumes of knowledge it takes to rebuild one of these, and we dont expect that you would. Any work on your transmission should be done by a professional, otherwise youll 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 is by no means a comprehensive examination of every component that is involved with the transmission (that would take a book to do). Here is just a peek inside and some clues as to what it takes to put a transaxle together.Ryan Lee Price and Timothy N. Gavern
Once the pinion assembly is in position, one side cover and bearings must be installed and a perfectly flat magnetic plate is attached to the top of the pinion shaft to help determine its depth. Then, an extremely expensive tool is used to determine the correct pinion depth down to the hundredth millimeter. The photo on the left illustrates the position that first gear would be engaged on the pinion shaft, and the photo on the right shows second gear engaged with the syncro operating sleeve.
This shows both sides of the final drive covers, which are commonly called side covers, where the axle shafts originate. This is a common example of a swingaxle, full syncro, tunnel style transaxle.

With the pinion depth established, the ring gear can be installed and its backlash adjusted to help achieve a smooth operation.
The pinion gear is at the top with first gear through fourth gear displayed in order from right to left. 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, essentially making it integral to the pinion shaft. On the bottom is the main drive shaft in which first and second 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 final drive set of gears used to lower the overall ratio of a transmission.
Here is the completed assembly, with the gear carrier, ready to be fitted into the transaxle case.
On the left is the nosecone, or gearshift housing, and on the right is the gear carrier, which fits on the front of the transaxle case.
With the gear carrier installed, the inner shift (hockey stick) and gearshift housing (nose cone) can be installed.

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