Broken Gearbox - Phase 4b Swap Gearbox Parts

Broken Gearbox - Phase 4b Swap Gearbox Parts

Phase 4b of the gearbox replacement is to continue swapping over parts & re-building of the replacement gearbox for installation.

Phase 4b was to complete the following:

1. Finish Gearbox mounts installation
2. Starter motor earth lead & Reverse switch cable
3. Gearbox plugs & Refill gearbox
4. CV Joints & Boots install on van

Finish Gearbox mounts installation

After last phase 4b I had to continue to get the EMPI aftermarket mounts on the gearbox cradle.

EMPI gearbox mounts:

The curve of the mounts did not quite match the curve of the cradle BUT once bolted down all seems good.

Close up of rear mounts & Fount mount

Starter motor earth lead & Reverse Switch Cable

Attached the starter motor to rear mount. Cleaned up contacts to make good electrical connection as this is stater motor and also engine main earth connection.

The beetle gearbox has another front cable (to the right of image above). This was to connect to the front mount. I will purchase a new one and add one anyway. The Brazilian Bay does not seem to bother with this one. It just relies on the rear connection through the cradle and onto the gearbox chassis forks.

You can never have enough clean earth points!

Install the reverse switch cable loom after cleaning contacts.

Gearbox plugs & Refill Gearbox

Installed lower plug and refilled with clean new gearbox oil. Filled 2 Liters of 75/90w GL-4 Semi-synthetic oil. Could do with topping up. Will drain and refill again after a few hundred miles.

CV Joints & Boots install on van

Finished cleaning the Beetle CV joints. One on the right hand side is a much stiffer than the left. Washed in Petrol then brake cleaner solvent. The coated with WD40.

Back under the van again. Installed CV Boots onto driveshafts. Gosh that was hard! The rubber is very tight and pushing the rubber boot over the driveshaft was fun! Managed to wiggle & rotate and push all at the same time.

Then it was concave washer, CV Joint, C Clip. Sounds simple but packing them with grease was hard to get in all the bearings. Messy job but all sorted.

Have not installed boot outer clamps yet as wanted to get the CV joints bolted to the replacement gearbox in place first to get boot distance correct. New boots are very good and flexible.

Boot in place

CV Joint Installed

Bolts are just to get alignment of boot to joints. Remember to get your clamp on before your boot!

There was some extra distance of the drive shaft to either the C-Clip or concave washer. Not sure if this is an issue BUT I suppose when CV is bolted firmly to the gearbox the joint will not move. 

So we are already to go to the next phase 5 - Replacement gearbox install!

Gave up a little early and finish by 10pm as I was tired and it was starting to rain.

Phase 5 Gearbox install on Friday! Finish work at 3pm so might be able to get install completed in one go........ Stay Tuned.