Gearbox eh? What 'box, ratios, # of gears are you running Dean??
This is the diary of the gearbox build that Dave did for me. The gear ratio's are down in the middle of the list. Hope it helps others when their looking at improvements on their box.
March 2010: strip and asses core trans(1968 beetle swingaxle).
Cut off axle nut to remove stripped brake rotor.
Supply two USED axle nuts.(free)
NEW seal for nose cone selector shaft.
NEW nose cone bush outer.
NEW nose cone bush inner.
MACHINE nose cone face flat.
NEW steel thrust plate for under nose cone.
WELD selector shaft end for improved shift quality.(and account for wear...nickel welding rod).
Supply USED intermediate housing to suit later bearing and main shaft.(free)
Supply USED hub for splined later main shaft.(free)
NEW 091(2 lt bus) circlips for later main shaft.
NEW German FAG brand main shaft ball bearing.
NEW Diehl brand synchros where required.
WELD clutch fork arms fully.(originals are only spot welded).
Supply USED clutch fork, arm, and hardware.
Modify,MACHINE late clutch fork (20 mm) hardware to fit Rhino style (16 mm) case.
Supply material and MACHINE special bronze bush for clutch arm conversion.
Supply 12 NEW nuts and hard washers for axle tube flanges.
Supply USED 1.3182 ratio third gear.(old ratio was 1.26).
WELD and MACHINE third and 4th gears, and hub to suit late style main shaft.
Supply USED metal caged needle bearings for all gears.(old ones are plastic cages and shorter needle bearings).
Supply pinion shims (free) and set crown wheel and pinion pattern, in new case.
NEW ERCO brand chromoly pinion bearing retaining plate.
Supply special wave washers for above.
NEW FAG brand dual taper bearing for pinion.
NEW input shaft seal and gasket set.
Supply USED input shaft (free), and MACHINE for rotary engine (length).
NEW shim for first gear end float.
Supply USED nut for first gear inner bearing race.
MACHINE all gears to control end float.
NEW SKF brand diff ball bearings.
NEW genuine VW diff shim.
NEW Japan wheel bearings.
NEW axle seal kits.
Supply USED steel fork for 1st and 2nd.(original one is weak brass material).
NEW Albins First and Second racing gear set and main shaft. 3.333 ratio for 1st and 2.0769 ratio for second.
NEW RHINO gearbox case.
NEW billet aluminium side covers.
MACHINE side covers to clear Rhino case internal casting.
MACHINE side covers and Rhino case for extra through bolt modification.
Supply long stud and new nuts and washers for above mod.
MACHINE intermediate housing to re-bush shift rail holes.(restores shift quality).
NEW special 15 mm spanner size nuts and washers for side covers(16 x).
Various solvents sealants and consumables.
Total labour and machining time 28 hours.
Finished 5th May 2010.
I've got a couple of pics if you need them.
