Hey could any of you tell me what mods I should do to my gearbox when i rebuild it so it performs better and is stronger?
Thanks a bunch.
-Staggers.

performs better? ie: faster accelerating or better cruising RPM on the freeway?
I've read that the 3.88 final drive ratio is the strongest and gives the best fuel efficiency on the freeway due to the taller gearing..

So by reducing the ratio from 4.125 to 3.88 I'd have a higher top speed but slower 0-60mph time wouldn't I?
-Staggers.

yeh, that's right. But ask yaself how often are you gonna go barney from the lights to drag off Nanna Beryl in her Kingswood to 100.. or 60...

Also, if you wanna fit wider wheels on ya car, use the shorter early axels.

What engine will it be mated to?

What will it be used for? cruising / street / drags / circuit / etc

What car will it be in?

What's ya budget?

I'm sure you can get custom gear ratios too. Seems like ppl usually change 3rd and 4th to something else to suit their needs (better acceleration or higher top speed) Some even weld 3rd and 4th together, don't know why, for strength I'm presuming?

It'll be mated to a 1600TP for now, in a Superbug preferably for circuit. And budget, what should I realistically expect?

I had a superbug tranny completely overhauled by a specialist, replaced worn parts, changed 4th gear set, all for less than $800. For a 1600 that should be OK.

If you are wanting to compete then idealy you will want custom ratios, quality diff, etc. Then you had better have a thick wallet. A second hand LSD alone can be over a grand!

German Autos in Brissy does heaps of trannys for off-road buggies and would be worth talking to (unless you can do the work yourself, but that generally requires specialised tooling).

Specialised tooling? Like a press and stuff?
-Staggers.

I don't know specifics, but I think you need special VW gauges, mandrels, drifts, blah, blah, ..........

I don't even think any old transmission shop can do VW stuff too easily. (could be wrong though)

You need more than just a simple press! Yes they are complicated to asembl - well, not compliacted, but you need special tools and the experiecne to use them - and there are all sorts of combos of ratios etc some of which do and do not work inside different cases and with different diffs. It's not DIY!

There are two ratios available in gearboxes that will slip straight into your Super - one with a 4.1 diff and one with a 3.8 and contrary to popular opinion, the overall top gear ratio is very similar BUT the 4.1 will give you better acceleration down low

A 'full house' comp VW gearbox with LSD and aftermarket ratios will cost in excess of $4K

Save your money for now and spend it elsewhere (handling, tyres, engine etc etc) Depending on what you mean by 'compete' you will be able to do track work on second-hand gearboxes

Tricks for now are to make sure the shift-rod bush inside the pan tunnel is new and has no slop, the rubber coupling has none either, and the gearbox 'extension housing' (where the shift rod pokes out) has 100 percent zero slop - if it does, find and transplant one that doesn't

New oil and some shift improver goo is agood idea, too



[ Edited on 9-3-2006 by VWCOOL ]

I can second Lawrence's work at German Autos - he rebuilt both my swing axle box (3.88 r&p, standard ratios (1500box) but welded 3rd and 4th gears, heavy duty (billet) side plate, super diff (threaded) etc) and my mate's IRS close ratio tranny (aftermarket 3rd and 4th (1.04 from memory), custom super beetle mainshaft, again welded 3rd and 4th, heavy duty single side plate, super diff etc).

I brought in the super diff and side plate - from memory around AU$600 but it was a long time ago so could be wrong (this included freight from CB Performance). Box was $800 to recondition from memory. Very happy thus far!

Our 61 ghia needs to have the box rebuilt.........It is linked to a 1600, so assume it isnt the original box?

Any ways, everyone in Melbourne has quoted me $1600+ for a rebuild on it (including the $300-350) to swap it out..........Anyone know where I can drop a tranny off in Melbourne and have it done for $800?

Cheers,
JRW

Get a quote to freight it to Brisbane

or buy a 2nd hand one in Bris and get them to rebuild that and only pay to ship down

Them you have a spare to boot - or sell and recoop some costs.

I am sure some one would have one up there - may be give Buggy Brad a call??

Volkwerke In Greensborough have a very good name for building VW Transaxles. We got out 2 litre kombi box done there and I am very happy with it. I dropped the box in to them and fitted the rebuilt box myself. Worth a call maybe?