After finding out that the loud 'thud' noise is due to my gearbox moving while accelerating, having no 1st or 2nd gear anymore, and being able to move the gearbox with my hand, i will be attempting to replace the front mount over the weekend.

Now i've removed the engine numerous times, replaced rear axle boots and replaced the rear mounts before, but have never had to touch the gearbox. I'm after any tips, do's, don'ts, don't forget to's, must have's, etc to make the job easier and smoother.

I have numerous books on hand and have copy of the BUGME video ready to go, so is this enough info?

Cheers

Your in for a treat......painful job getting the tranny back far enough depending on vehicle.
IRS or swing, beetle?

it can be done with the engine in


BUT i would pull it to make it much quicker and easier job

Make sure you do all 3 MOUNTS

61 Beetle, swing axle and i replaced the rear mounts about 6 months ago. I can usually have the engine on the floor within 20 minutes, so how many hours will this roughly take a first timer?

As Dave said pull the engine,let the gearshift rod go,undo the big bolts on the mount bracket,then using a couple of beetle jacks between the body near the front mount and the axle tubes,push the trans back carefully and evenly just enough to get the mounting out.(I suggest that you tie the jacks in place to prevent them slipping)slide the new mounting into place keeping your appendages(fingers, toes,hands,head etc clear),release the jacks evenly & carefully lining everything up as you do.I have used this method a few times but I MUST stress be careful,make sure the car is supported on proper vehicle stands and under no circumstances put your fingers or hands between any items whilst working.The other alternative is release the axle tube mounting bolts to allow the trans to slip back.
No resopnsibility taken for any user of this advice as I am not in control of your work practices. Cheers Les

Consider a Berg / Porsche style brace

http://www.ebay.com.au/itm/VW-Volkswagen-Beetle-BERG-PORSCHE-STYLE-GEARBOX-BR...

I am sick of cheap mounts
I have replaced and had the same issue come back within months - twice

This WILL fix it
Yes it will "harshen up" the vibrations through the car - but I am now use to it and I STILL have a great mount

Defiantly go the mid mount. Stops a lot of flex and move t. So add a support brace under engine supported at bumper supports. Stops engine pulling down and breaking things

Do these braces require welding or other modifications to install? Where do these bolt to underneath? I guess it would be easier to just install a brace under there instead of removing the engine, gearbox, etc to swap a $15 part.

yes - you need to weld the "tabs" on

yes - your car is a LOT more "harsh"

yes - you have NO more worries about front gear box mounts

Tip; loosen the spring plate-axle bolts to allow movement of the trans rearward, don't forget to mark thier location so they can be refitted the same.

This is one of the things that has annoyed me about Beetles for years.

It would have been very easy to have changed that mount back in the 1930s, to one that can be replaced without having to move the engine etc.

Can you image the language of the first mechanic who crawled under a Kubelwagen in the mud of a WW2 battle field and saw what he needed to do to change the front mounting?

I belive that the Type 3 has a better mounting.

The early mounts didn't have the tongue to mount into the frame.

Done. Finally finished the job, in between packing to move house.

I played it safe and followed the BUGME video, removing the whole transmission and dropping it to the floor so i could check for any other damage. Wasn't as hard as i thought it would be. A few things slowed me down though: waiting for a borrowed 19mm wrench (mine's gone missing), and then the 19mm axle/torsion plate bolts were stubborn and took about an hour of hammering, spraying with WD40 and swearing to come loose. Other than that it was a smooth repair.

I dropped the engine and transmission 2 days ago, sussed out the parts needed, drove up to Vintage Vee Dubs yesterday, and replaced it all today. At VVD's i picked up a front transmission mount, a nose cone to chassis rubber boot, some leads and a quiet pack exhaust to replace the rusted and beat-up Phat Boy exhaust which i was running.

Now the only thing left is to get the reverse lock-out plate in the right spot so i can get all gears. I can find 1st but when i shift it goes to 4th, not 2nd. Or i can move the lockout plate to find 2nd, and take off in 2nd, shift to 3rd and 4th, but it won't find 2nd or 1st when down-shifting.I had this problem last year and took my ages to find the sweet spot. On the upside, my 4th gear doesn't pop out anymore!