091 build for turbo bus

[kubelguy13]

All gears washed, syncro clearances measured, check out good, slider fork pads good.
Chromoly pinion nut needs the spacer underneath as I have a later model case. Hand pack bearings for 1st and 2nd, special bearings for 3rd and 4th Albins not Weddle gears. Split cage bearing is for fourth I think? 3rd gear is 1.14 and 4th gear .70

[Pablo2]

Turning torque can be measured with any good quality 30 in/lb torque wrench. But this is not a critical procedure, and can be skipped if the bearing "feels correct". Measuring diff bearing turning torque is far more important.

I reversed my opinion many years ago on the use of loose needles. 1st & 2nd gear only, and ONLY on a drag race transaxle. Otherwise, they are just a source of unwanted friction. Visualize how the needles are bumping against one another as they roll, and be aware that all needles migrate toward the larger side of idler bore. Bores are rarely perfectly true.

[Pablo2]

Did those 1st-3rd gears originally come with moly coated synchros?

Weddle had a sale on 091 1st & 2nd idlers recently .. great incentive to install new.

[kubelguy13]

I have new syncros from the Long transaxle rebuild kit.

[kubelguy13]

I have a Weddle 3rd and 4th gear. Are they supposed to be welded?
My 1st and 2nd gears are original VW.

[kubelguy13]

Should Syncros be lubricated before fit onto the gear or pressed on dry?

[kubelguy13]

I have pressed 3rd gear as far as my press will take it and there is .013" play for 2nd gear to 3rd. Should these be flush? And the snap ring is supposed ot have play but has none on the old ring and the new ring will not fit. Weddle 3rd gear stock 2nd gear.

[Pablo2]

Lube everything during assembly. Generally, you should not replace moly coated synchros with plain ones.

Those engagement teeth are now free floating on the splines. They were a tight press fit in years past.

The spacer circlip comes in different thicknesses, from 1.6 - 2.4mm

[kubelguy13]

Weddle 4th doesn't have a shoulder like my stock 4th gear.

[kubelguy13]

Some progress.Installed gear stacks in gear carrier.Set shift fork adjustment and reverse gear( Reverse idler gear clearances were trickiest to set.) then installed in case. Then noticed a crack in gear carrier. Not sure if i did this pressing the main shaft bearing in or if it was already there. Another one in my parts pile is also cracked same location. Im hoping its ok or can be tig welded.

[Pablo2]

If you see exactly the same "crack" on two different housings, I suspect it's actually a casting mark. I've been fooled before, and could only tell the difference under 10X binocular magnification.

[Steve Arndt]

What if you polish it with a cartridge roll in a small area and check if the mark is visible afterwards?

[kubelguy13]

When sealing housings togetehr with paper gaskets and using the metal reinforcement for the shift housing what silicon or sealants would you use?

[Pablo2]

I omit the paper gasket and use anaerobic sealant like Loctite 574 or Wurth orange flange sealant on both sides of the plate. On oil-fed transaxles, I'll then use grey automotive silicone sealant as a secondary seal all the way around the exterior edge of the plate (after meticulous cleaning with alcohol).

[woodsbuggy1]

Just curious as I have much to learn but I was under the impression that Albins is the company that makes parts for Weddle. Am I incorrect?
Thanks
Kenric