växellåda – MAINDRIVE

02Sep 2019

The Ghia project

Have finally got something done on the old VW Karmann Ghia chassi. Its being converted from swing axle to a better independent rear suspension. It’s just mocked up and tack welded at the moment, test fitted the new rear discbrakes. The fork/frame have been clearanced for Porsche 5speed 901 transmission and also reinforced, welded all around. Probably I will reposition the IRS brackets further in, and mount the trailing arms on the inside of the springplates. Then I will get about 1″ more space against the outer wheel arch and can then fit wider tires. Driveshafts need then be shorter also of course, the left VW type 3 automatic driveshafts are shorter and would be perfect or buy new shortened EMPI’s. Next up is to fabricate front transmission mounts and 911 (or maybe VW) gear linkage.

16Jan 2017

Small update #highroofbayproject

by martin ⋅ Leave a Comment

Have not got very much done lately. As my first son (1 year old) takes most of the time now. So that more important at the moment. But Im trying to push forward on the bus too, couple of hours after work and on weekends etc. Soon have all doors and lids in primer and then it all just needs a easy sanding and then its time for a paintjob! Have also sandblasted the fueltank cover and bellypan and got them painted and ready too. Hope to start rebuild of the 1800cc Type 4 engine in begining of February also!

More to come, but thats it for now, here is some pics…

Blasted and epoxyprimer, ready for topcoat in VW factory greyish

Baremetal then yellow epoxy/zinc primer

Topcoat in VW L20a Marino Yellow with 2K polypaint with elastic characteristics. So the stones wont chip the paint. The gloss on the elastic is a little less, but this panel is under the car and you normaly never see it anyway.

12Sep 2016

Transmission service

by martin ⋅ Leave a Comment

Have been working on the transmission and driveshafts lately. Had a pile of new parts from Just Kampers waiting for it. The tranny was in very good shape and have been restored by VW (exchange parts) in the 1980s. But it still needed alot of work to look good again. Highpressure washed the case 3 times, to remove dirt and old oil. Drained the oil and it still looked nice (good sign)! Then 3 coats of paintremover was added so the black paint could be peeled off the case. Degreased it one more time, wirebrushed and sanded it making it ready for paint. A coat of primer for aluminium/etch was layed down and then 3 coats of 2K silvermetallic paint on top.

A new mainshaft oil seal was added, and both driveflange/shaft seals too. The nosecone got a new reamed bronze bushing and oilseal for the shiftleveler. Also the small plastic balljoint in the end of the shiftlever (the one that pushes gears) was replaced to a new made of steel, and will last a life time instead of a brittle plastic part that was before. The shiftrod feels very accurate and precise now, no more sloppy gearshifter! This is also a popular upgrade on VW race transmissions. Driveshafts and hubs was sandblasted and painted. New groundcable to chassi. New clutchwire. New gaskets, rubberboots and CV joints installed. New startermotor + bushing mounted too. New trans mounts upper and lower. And then the transmission was filled up with new fresh mineral API-5 grade transmission oil that VW recommended on these 002 cases. This oil is extra good to the special metalparts like syncro rings etc. Not aggressive like other grades can be to these old transmissions. Here is the pics…

18Apr 2016

Transmission service

by martin ⋅ Leave a Comment

Stephans VW Bay project moves on and here is some pics from the transmission overhaul made last week here in the garage. The transmission is a 002 case, 3 rib from late 1973. Code CK. The Baywindow buses are famous for their poor gearshifts. If you have a sloppy gearstick on your bus, first check all bushings in the gearlinkage that runs thru the floor from front to back. If the shifting still is bad, then its possible that the gearleveler balljoint (made in plastic) inside the nosecone is worn out. I replaced this balljoint on this tranny for one made in metal instead, so it will last for ever! The magneticplugs was cleaned, oil drained, all gaskets and seals new and then a coat of fresh paint. Now its ready to be bolted back in the bus again.