Showing posts with label transmission. Show all posts
Showing posts with label transmission. Show all posts

Thursday, January 12, 2012

Driveaxles Named Desire

Ready for the driveaxles
With the front beam, transmission and trailing arms all back on the frame, it was now time to rebuild and install the driveaxles.

Before I could get to that, however, I had one more small detail which I mistakenly thought was going to be no more than a 'cosmetic' re-installation: the cover plates and bushings for the rear torsion bars.

Off by quite a bit
The torsion bar cover
The covers and bushings came right off, but of course the old bushings were all deformed and it did not occur to me that these new bushings would throw off the alignment of the cover plate, but of course, that's exactly what they did.  After a few minutes of frustrated observation I decided that this was one of those 'stuck' moments and I decided to simply put it off until I think of a solution.  I have some ideas, but there is no pressing reason to put these parts back on at the moment, so I'll just let it simmer a bit in the back of my brain.

The new cv joints look good
Especially when on the axle
In the meantime, there is plenty to do, starting with those driveaxles.  I tore down the old ones some weeks back, but concluded that for such important parts of the drivetrain, it was worth the expense of buying brand-new constant-velocity (cv) joints.  The parts I took out look ok, but tolerances run in the thousandth of an inch and given how key these little parts are, I want it to work right the first time.

Ready to assemble
Ready to install
The driveaxles themselves were just fine with a buff and a coat of the rubberized undercoating paint.  I installed the new cv joints and the fresh new rubber boots that cover them, then smashed the graphite grease that came with each joint in and around all the bearings and moving parts.

The gooey mess...
Installed!
Then I had to take the whole sticky gooey mess and mount it into the nice clean space between the transmission and the trailing arms.  This was nearly a disaster, as the cv joints on one end managed to fall apart as I was lifting the other end into place.

Despite the drama...
The scene was straight out of A Streetcar Named Desire:  I was on my knees in the driveway, covered in sticky graphite grease, holding the broken bits of the cv joint, and almost literally weeping with frustration.  Fortunately before the neighbors came running over to find out if I was having a heart attack, I managed to seize control of my emotions and the damned joint, muscling both into position with a great sigh of relief and a furtive look to see who had witnessed the sorry scene. Fortunately it looked like I was alone in my chagrin as I loaded up all the freshly cleaned and buffed bolts (the object of much difficulty on removal).  Before long the driveaxle was officially installed!

The job is done!
As is my habit, this first half of the job was completed just as the sun was going down, so I turned my attention to the other side with no time left on the clock, so to speak.  However, with the experience gained and without the emotional meltdown, I managed to work quickly and efficiently, installing the other driveaxle without incident and just before it was too dark to see.  This sort of thing always leaves me in a state of doubt, but on my return the following morning, I found the work to be done right.  Woot!  I cleaned up the excess grease and checked this task off my list.

Next:  Brake system, beginning with the front rotors and calipers.

Thursday, January 5, 2012

Paint, Transmission and Trailing Arms

Once the underside of the frame was finished, it was time to turn it back over and begin work on the top half.

Rust...
...insidious rust
Basically, the work was the same as it was on the other side.  First I had to remove the spots of rust that had spontaneously appeared on all the bits of freshly exposed steel.

Cleaned and sealed
Ready for painting
Next came the top side silicone seal which effectively blocks any moisture from working it's way into the interior via the floor pans.

Primer for the fresh bits...
Undercoating over all
Then, I sprayed some primer on all the bare steel spots and finished off the whole deal with another couple of cans of undercoating.  Even though there were a few spots where the paint wrinkled up a bit, for the most part I got a nice smooth and even coating.

Both sides now
Paint looks good
Although it looks good, it's hardly finished.  I will be putting down some sound-deadening material on the interior side of the floor pans, as well as another thicker silicone seal for the edges that will really make it a tight fit.

Time for the tranny
In without a hitch!
With the frame finally painted, it was time to begin re-assembly.  I started with the transmission.  First I had to fill it with fresh gear oil.  Next I assembled the mounts and cross brace, fit the new rubber nose gasket into the frame and lifted the whole thing into place.  It slid right in and when the big bolts on the front were tightened down, it looked perfect, just like a brand new piece.

Still painting things
Trailing arms are ready to install
The next day, it was on to the trailing arms, which had to be re-painted and installed.  Because I'd done this twice already, it was an easy job.  Both sides went in just before dark.

Front beam repainted
...and reinstalled!
After that, the front beam, also freshly repainted, went back on, with the help of Valery and Madelaine.  Previously I had thought I could just paint the beam and leave a lot of the parts (like the nuts and locking screws) unpainted, but even though we've been in a drought, when it finally rained last month, all those unpainted pieces developed a fine patina of rust.

All the bits were painted
No more rust!
So, I had to carefully wire wheel and sand off all the rust then coated the entire beam with a fresh coat of hard gloss black paint.  I also cleaned up all the bits and pieces, painting them separately before putting them back on.  The end result was most impressive.  It really is starting to take on the quality of a rebuilt machine.  It's not a show car, but all the pieces are there, all painted and perfectly assembled.

Next: driveaxles, re-assembled and installed.

Monday, May 23, 2011

Gearbox

With the trailing arms out and off to the machine shop to receive their new bushings, it was time to pull out the transmission.  I like the British term for this piece better--gearbox--because it sounds racier I guess, but by either name it had to come off the frame for cleaning and inspection.

This is not a difficult job--unless the body and engine are still attached, and even then it's fairly straightforward.  It's attached in just three places, so it was a simple matter to unbolt it and lift it off the frame.  I set up a hydraulic jack underneath just in case, but as it's made of aluminum, after the bolts were out and the shift rod was detached, I was able to simply pull it out and set it off the the side.

The gearbox is dirty but looks to be in good shape.  Although it had a fair amount of crud built up, particularly around the driveaxle connections, it doesn't appear to have been leaking, at least not too much.  The layer of crud is either a bit of grease that oozed from the front seal and has been collecting dirt for thirty-seven years or is just mud and dirt built up in those places you expect it to.  The 'guts' of the gearbox are relatively hard to wear out, so when I check the fluid if it's free of contaminants (especially metal) I will assume that it is ok and just clean it up before putting it back in.  Of course, if there are metal flakes in the fluid, it will be time for a trip to the junkyard.

Speaking of the junkyard, I took the trailing arms in to Austin V-Dub last week to have the bushings replaced and it was a lot more expensive than I thought it would be.  The guy just called to tell me that they are ready and the total came to over $650.  Now, to be fair, $250 of that is actually for the front ball joints, which are being replaced as well.  Although the $400 for the rear trailing arm bushings is a lot of money, I really don't have any choice.  For one thing, the bushings are no longer common, and of course replacing them is no longer a routine machine shop chore.  Fortunately the guy at Austin V-Dub is older and knows what he is doing, which is--of course--a lot more than I can say for myself.

While waiting to save up the money to get my heavy metal parts our of hock next week, I turned my attention to the front beam.  Although I had not intended to pull this off originally, after the work I've done on the rear it seemed like the consistent--if not easiest--thing to do was to pull it off, clean and repaint it.  Just four bolts hold it on, and in just a few minutes my decision proved to be worth it, for the rust and grime I discovered was considerable and I'll feel a lot better about it knowing it's clean and tidy under there, even if no one will ever see it except for me.  This task also meant that my dirty days are not over, as the broken and rusted lower torsion springs left quite a gritty mess inside the tube.  That stuff had to come out, and all the surface grime and rust had to be whisked off the frame with the wire wheel.  Then I  primed and painted the beam, but since I didn't clean up the mounting bracket on the frame, I will have to wait to put it back on this weekend.


That is, if I have time.  I am working all three days so hopefully I will earn enough cash to go get my newly refurbished parts for the following weekend.  Then, watch out!  This baby's going to start going the other way!

Monday, May 9, 2011

Driveaxles

While I am waiting for an bolt of inspiration that will loose the stuck nut that hinders my progress on removing the right rear wheel, I decided to work on something else, knowing that there are others things to work on and hoping that progress there would raise my gumption level and break the impasse that stalled me for a week or more.

Although I don't intend to rebuild the engine, I find that term 'rebuild' to be a bit flexible.  That is, because I have removed the engine, there are many parts of it that I will remove, clean, repair, sand, paint and replace as part of the overall refurbishment.  These are things like the alternator and fan, the 'doghouse' shroud that holds that fan and covers the oil cooler, the carburetor, the intake manifold and the alternator pulley.

None of these things need to be replaced, just cleaned, painted and reassembled.  The engine has, from the beginning, looked to be in very good shape, and when I got all that stuff off my hopes were buoyed, if not actually confirmed.  The oil that I (finally) drained from the crankcase was dirty but not contaminated with any metal that I could feel.  For some reason, I have yet to conduct one of the easiest and most basic tests of an engine's condition, the spark plugs.  I'll have to do this tonight.


Once I had all the dirty (but not rusty or even bent) shrouding removed and buffed the dirt off the head covers, I discovered a little tag that says "Made in the Netherlands".  I am not sure if this means the whole engine, or just the head cover, but it's an interesting discovery.  At this point I stopped and put the engine aside, but before I put it back together, I will consider removing and/or changing the heads.  I plan to put in dual carbs, so it may be that some new (or rebuilt) heads would improve the engine performance enough to make it worthwhile.  I'll 'save' that for later.

The next task I turned to was removing the driveaxles.  This job required buying a(nother) new tool--which came as part of a set of three--to remove the bolts that connect the two ends of the driveaxle.  The driveaxle connects the transmission to the wheels, and removing it is the next-to-last step in the tear-down process.  When the body is still on the frame, this in one of the hardest to reach and dirtiest places on the car, but as it stands now, it's very easy to reach.

These bolts are still plenty dirty, though, and to make use of the tool without stripping out them out, I had to make sure all the little splines were cleaned out thoroughly.  These bolts are unique to VW's, and are apparently still in use on today's cars, so you won't find the tools to remove them at Home Depot, or even Freight Harbor.  I had to order them online. It was certainly worth the expense and the wait because it really does fit at both ends: into the bolt heads and on my ratchet.  It was a little scary, at first, using it.  It felt as if it was going to strip like aluminum, but a little extra leverage was all it took.  In no more than ten minutes, all twelve bolts and the driveaxle were out.  Although this was dirty, it doesn't appear to be damaged or rusted, so it's likely that a simple clean and re-grease is all these parts will need.

After both of the driveaxles are out, I can remove the transmission.  Like the engine, it looks to be in pretty good shape.  I'll have to drain the fluid and see if there is any metal in it, and decide from there whether or not I'm going to replace it.  This is another decision to be made down the road, so to speak.

Next I will turn my attention to removing the diagonal swing arms, which connect the wheel bearings to the frame of the car.  This is more heavy metal work and may even require one more special tool, but it will be the last (major) part to come off the car.  There are still a number of pieces to come off the frame before it can be cleaned, sanded and painted, so I can't say that the teardown is at an end, but I am getting close!