Gearbox Replacement Procedure

Brazilian Bay - Gearbox Replacement

This is a summary guide of my Gearbox replacement.

The Brazilian Bay Kombi gearbox is made in Brazil and is known to have reliability / poor quality manufacture and is best replaced by a German Gearbox.

Here is the progress summary of my Gearbox replacement. Basically its a Late IRS Beetle Gearbox from a 1300-1600cc Late Beetle (1302/1303s Models with the 1600s being the best)

In this case I swapped the RP code Brazilian Bay Gearbox with a 1302s 1600 AH code gearbox

Firstly find and select a suitable gearbox here is my AH code gearbox (new CV joints or Beetle CV joints are required as beetle Gearboxes have a 94mm Diameter CV joint and Bus / Brazilian Bays use a 100mm so you will need to have Bus Outer & Drive shafts and Beetle Inner CV joints)

You need to clean the gearbox and remove old CV joints.

Remove rear bumper & Valance:

Remove Engine:

Remove Old Gearbox:

Swap Over Nose Cone & Hockey stick from Old to new:

Install Beetle CV Joints on van:

Install new gearbox & connect up:

Refit engine. Test gearbox while still on axle stands to ensure all gears work.

Once satisfied away you go with a German Quality Gearbox.

Full comprehensive write up of each phase of my install is on my T2bay bay blog.

http://t2bay.blogspot.co.uk/

I will include this in a full step by step guide in the next version of the service manual also found on my blog.