CHE 16093

$1100 shipped *sold*

Parts laid out ready for cleaning...

Case insides cleaned out fully, ready to be sealed up in preparation for the blasting work...

Case assembled with all holes sealed with bolts or rubber. It stops most of the sand from getting in, but not all of it. Sand gets anywhere and everywhere. After blasting, the case is rinsed and dried and blown out several times over to make sure everything is clean.

Update 7/01/08

Internal parts cleaned and spread out. They need rinsed and oiled, then assembled...

The case is blasted, but there are a few spots that are still stained, so I am going to sand blast the case one more time.

No pics of the build process, but here is the completed trans. The case was sand blasted, then glass bead blasted. The flanges, release arm, and drain plug were sand blasted, the zinc plated and chromate dipped for corrosion resistance...

The parts that were replaced in the rebuild (pretty much everything but shafts, hubs, gears, and the case); everything is OE VW, or from the OE mfg.'s, unless noted (like the Peloquin bolt kit, or the sync rings form Argentina)...

Bearings
diff taper bearings
output shaft taper bearings
output shaft roller bearing
input shaft ball bearing
input shaft roller bearing
needle bearings for 1-5 gears
TO bearing
 

Seals
Flange seal kits
input shaft seal
pushrod seal
pushrod bushing
selector seal
release arm seal
green end cap
green seal sleeve
case sealant paste
 

Syncs
RFI Brazil 1st gear sync ring
Argentina brass sync rings 1-4 gears
sync keys
sync springs
 

Circlips
4th circlip
3rd circlip
input shaft circlip
2.3mm diff circlips
 

Misc.
output thrust washer
5th fork plate
5th bolt
Peloquin bolt kit
plastic diff thrust
starter bushing
20mm detent bolt
actuation finger

 

 

Teardown 06/19/11

These are the used bearings, there are 2 pics of each race.

The race on the drivers side...

The passenger side diff race...

The small output shaft bearing race...

The large output shaft bearing race, in the retaining plate...

This is the finger out of the rebuilt trans, you asked for new in your email, this is about as close to new as you can get. You can't feel the wear line with your finger, but you can see where it contacted the bearing...

The used reverse idler out of the trans... I am going to look for a better used gear for you, this has a little more wear on the tops of the teeth than I would like to see....

The used ring gear on the diff, bolted in place

The new 2.3mm clips and the black plastic thrust piece behind the spider gears...

The output shaft...

The good used parts... 5 gear needle bearings, the 2 shaft roller bearings, the input shaft large ball bearing, the 3 sets of sync keys and springs, the circlips (2 for 4th, one for the input shaft, a 3.0mm 3rd), the thrust washer under 1st gear, the input shaft seal, release arm seal, and selector shaft seal. There are also 2 sync rings, the other 3 have been robbed from the trans at some point, so I'd use the 2 used rings on 4th and 5th, new rings on 1st-3rd. The actuation finger is in the lower right corner...

Update 06/21/11

Pics of the new Timken bearings being installed onto the output shaft and the diff carrier...