Broken Gearbox ;-(

Broken Gearbox!

Thursday 16th June 2016 is the day my Brazilian Bay Gearbox Died!

The Incident:

Never been very happy with the noises my gearbox in my Brazilian Kombi made since I bought it, always wining when de/accelerating and trouble selecting 2nd gear.

Today was the day it finally gave up. Reversing off the drive in the morning is always tricky as the Chelsea Tractors going to the grammar school always speed down our road. I saw a chance to reverse out and a 4x4 was coming fast down the road. So once out I decided I better get moving fast so into 1st gear and up rather rapidly with the clutch. Slight wheel spin on one rear wheel and the other took grip.

Lots of shuddering as the van started to move and van popped out of 1st. Shoved back into gear and started moving away slowly and a horrid noise every rotation of the wheel like a clunk-clunk noise emanating from the gearbox on the left.

Tried 2nd gear and same noise and crunching and grinding sounds. Made it round the corner frantically selecting any gear which would not grind. Did a random U-Turn and made it back to home.

So I think the differential or final drive has gone and the gearbox is eating itself internally from within.

The Replacement Choice:

So I was on the hunt for a new gearbox. Many options but no Brazilian OEM gearboxes available and would not want another poor quality gearbox again.

So the Brazilian Kombi uses a hybrid gearbox which is mounted from below at the rear like a Late Beetle IRS gearbox (mounted on two forks which come out from the chassis. The front of the gearbox mounts similar to a late bay with a longer nose cone.

So the hunt started for a Late Beetle IRS gearbox. From the on-line gearbox codes my options are:

CODE	1st	2nd	3rd	4th	Final Drive	Rpm @60mph	Info Year / Type / Engine cc
Brazilian	3.80	2.06	1.32	0.88	5.143	3800	IRS from 97 1600 Brazil
AH	3.80	2.06	1.26	0.89	4.125	3100	IRS from 8/68 – 8/72 1500/1600
AS	3.80	2.06	1.26	0.93	3.875	3000	IRS From 3/72 1600 (GT)
AT	3.80	2.06	1.26	0.93	3.875	3000	IRS 1303s from 3/72 1600
AM	3.78	2.06	1.26	0.93	4.375	3400	IRS Saloon from 8/70 1300

Then using the on-line gear ratio calculation at:

http://calc.teammfactory.com/

You get a graph for 2 different gearboxes (original and replacement)

As I suspected the Brazilian gearbox Ratios are higher rpm in 4th gear at 60 mph topping a 3800 rpm. I have found that the engine RPM is very high when traveling on a Motorway and fuel consumption is poor compared to a classic late bay.

I suppose in the heat, poor roads and steep inclines of Brazil you would want to keep more higher rpm for acceleration, lower top speed and better cooling running the higher rpm. In the UK / Europe you have more motorways and cruising.

Any of the beetle gearboxes are going to give a lower rpm in 4th gear. The downside will be slightly longer to get there BUT less engine wear.

So my options are:

1. NEW Brazilian - There are NO Brazilian replacements available in the UK. Also why would you ever want a low quality gearbox.
2. NEW Beetle / Bus - There are new gearboxes for Beetles / Bus available BUT at over £1500-£5000 way out of price range
3. Reconditioned - Many companies re-con old VW gearboxes - They nearly all ask for your old gear box in exchange or a surcharge. Some varying quality and warranty. Choose wisely and also they might not take your old gearbox and warranty issues if you remove parts from it and DON'T expect a straight Brazilian swap you will have to get a beetle and modify it to fit! Prices are generally £800- £1500.
4. Second Hand - There are some of the above Beetle gearboxes available mostly on e-bay etc. The lack of interest in late (1302/1303) IRS beetles helps but yet again there are not many about as most people exchange for re-con units. Again choose wisely. You will not get a warranty on a private sale. Some of the second hand parts suppliers do have them available. Prices Start from £150-£300

My choice was number 4 to go to the low cost risky second hand. The search found found that these are the typical prices.

Code AM £200

Code AH £280

Code AT £350

So as you can see the AT (1600 GT) is the most popular and rarer model. The AM is the basic 1300 simple model.

The Replacement:

So I looked on e-bay and found a few BUT I really wanted to physically see the gearbox to give it the once over before parting with nearly £300!

After ringing around found some US imports but not local.

Then I contacted my friendly local beetle breakers and yes they had a rarer 1302s (1600 model) beetle gearbox complete with CV & drive shafts. They wanted £300 But after a little negotiation I got it for £270 (Minus the starter motor)

So I could collect it on Thursday evening (same day as breaking it to sourcing a replacement!) Drove the 10 miles up the M1 in the most horrible rain storm to collect.

Here she is:

Not the most clean or best condition but the beetle had spent 20 Years under a tarp in a front garden. The history well the beetle had only done 34,000 miles and then was left in the garden. The engine (still working) was sold and the body cut up by the breakers as it was very rotten.

So next steps will to be continued as work progresses BUT the phases are:

Phase 1 - Clean & Strip New gearbox

Phase 2 - Remove Engine

Phase 3 - Remove old gearbox

Phase 4 - Swap Over old parts to new gearbox

Phase 5 - Fit new gearbox

Phase 6 - Refit engine

To be continued..... Stay Tuned for progress & updates.