Project Gearbox

Having taken apart and put back together most things on a MK1 I've never ever rebuilt an 020 before so am going to have a go with one I've had laying around for ages.

Seems your supposed to have loads of special tools etc so I thought I'd start by seeing how stripped I could get it with just the tools i had available.

Suprisingly I got the whole thing apart.

First few pictures……

stripped…..



Cases cleaned and bead blasted……





Looks oK inside. Did find a loose speedo drive inside though!

Next job will be to blast all the shafts and gears and measure the syncro gaps.

Quite funny about the speedo drive, suspect theres a few box,s running around with one of those in the bottom.

Is there no limit to your mechanical know how Yomp?

smudger1980 said

Is there no limit to your mechanical know how Yomp?

Proof will be in the finished article!
I've rebuilt a few landrover boxes previously but I guess my best work was rebuilding a gearbox on a 1932 3 1/2 litre Bentley.- Took 3 days just to get the box out the car!

Looking good Yomp, be interesting to see how to do this.

your allowed 1 gear, a round thing and 3 nuts and 1 bolt left ouer on a job like that mate,so dont panic lol
Bert

All the info is already out there.

One site I find useful is brokevw

Ive read through it a few times and it was a useful source when changing the 5th ratio in BB.

However it gives dimensions for some tools you need but not all.
I'll make any tools I need as and when I see fit.
I have various pullers and a decent press already which makes it a lot more viable to achieve.

Bert said

your allowed 1 gear, a round thing and 3 nuts and 1 bolt left ouer on a job like that mate,so dont panic lol
Bert

   

I refurbished a diesel box quite some time ago. I remember the main bolt of like 220Nm torque setting was a real pain to remove even with a 6 foot pipe as an extension bar! (was worried the pipe would snap or something)

I found new syncros, tabs and springs from VW which shouldn't be a problem as the part codes are used in many cars including porsches.

Do take care of the main big bearing when removing it, as I had thougt I found a new one to replace but when coming to reassemble the inner diameter was too large. Also the large washer underneath has a slight taper to it (on one side only) so make sure to take note of which direction it is in when dissasembling.

When reassembling the box if you don't have a press you can use the casing bolts to press the casing onto the big bearing( evenly tighten the bolts across from each other in a balanced way). When doing this make sure to place a block of wood to hold up the main shaft slightly (Clutch side)  and the bottom casing claped onto the bench such that the pressing force does not press onto the taper bearing.

For the new main bolt make sure the socket head you are using fits very tightly because they are made of a softer material. (Trust me you'll regret it once its rounded off and there's no way of undoing it except for welding on a nut or something which could affect the shaft)

Fantastic!! I've got a 02J on my 20v resto. Would that be do-able for a quite practical chap like myself??

Thanks Olly. I know about the 5th bolt. I've got a snap-on tool for that. Its the same size has the head bolts.

Two of the bronze syncros have a different finish to their tapered faces which i wasn't expecting as i thought the syncros were all the same.

10mm socket. - You need a few special tools, a press, decent puller. It really depends on your mechanical experience and tool availability.

Cleaned a few bits today…………..

Yomp said

Thanks Olly. I know about the 5th bolt. I've got a snap-on tool for that. Its the same size has the head bolts.

Two of the bronze syncros have a different finish to their tapered faces which i wasn't expecting as i thought the syncros were all the same.

10mm socket. - You need a few special tools, a press, decent puller. It really depends on your mechanical experience and tool availability.

Cleaned a few bits today…………..

Yes if I remember correctly the first gear syncro had a different part number.

Wow the shafts look good with the blasting. I had squirted some oil onto the needle bearings upon assembly such that the gearbox wouldn't start up dry, especially with the rougher surface from the blasting.

Also I remember that the bent end of the springs shouldn't be located at the same notch in the syncro hub to make sure the tabs press in evenly.

Looks like a good job