Broken Gearbox - Phase 1 New gearbox

Phase 1 - New Gearbox

Purchased a 2nd Hand Gearbox from the Beetle breakers. AH code from 1302s Beetle. IRS German built gearbox from the 1600cc beetle (approx 1970s)

This is how it arrived.

Its has sat for 20 years in a garden in the back of a rotting beetle. Supposedly only done 34,000 Miles and the engine was still running.

Its great that I still have the CV and drive shafts as these will come in useful later. Minus the stater and also the clutch return spring has rusted and snapped. Covered in grease (mostly CV and engine oil)

So drained the gearbox oil. Still nice and brown with hardly any metal fragments on the drain plug magnet.

Set upon cleaning it with clutch cleaner and a wire brush.

About half way through having removed some dirt!

Getting Cleaner

Cleaner still after about 4 hours!

So it was time to remove the CV Joints. This would be "normally" done when they are connected to the wheels but I did not have the option.

So improvised some angle steel to hold the outer CV joints in place. Using the 12 Spine socket away the come (remember to clean out the spline nuts of all grease and crud)

That's better nice and clean CV flanges.

Shame I am not as clean

Must be a case of "German Gearbox Measles"

Replacement gearbox stripped down so far. Have ordered a new Clutch return spring. Its going to be fun to fit without trying to take the clutch arm off.

That's it for Phase 1. Replacement gearbox Cleaned and ready.

Phase 2 - Engine out coming soon........ Stay Tuned.