Well, Valentino is not his real name, to protect the innocent,
but he asked me to assemble this tranny to go into his streeter 'super'.

There are not many things inside this tranny that would want anything better.
"V" was very good and had all his parts nice and clean, and after some discussion we settled on the following ratios:
4.125 diff ratio, on a rare ZF swingaxle limited slip.
(yes, in an IRS!...more soon)



FTC 3.778 first,
FTC 2.357 second gear,
ALBINS 1.722 third gear,
and what appears to be an old Hollinger
1.333 straight cut 4th gear.

Did you say 1.33 for fourth?
Yep, thats over 4400rpm at 100km/h!!

My normal first step is to set up the crownwheel and pinion.
This particuar case was quite difficult this time, because the shim that VW used was miles wrong.
After much trial and error I was able to use a 0.15mm shim to get the pattern as close as I could,
and used .006" back lash as the factory minimum.



Normally the shim is around the 0.5 to 0.7mm with this particular tooth form.
But as it was the contact was right on the tip of the pinion.
VW probably set it this wat because it was within their spec for silent operation with about 50hp.
It WAS centred height wise, but with so little contact it would have failed with the power that Valentino has.



Each time the pinion shim is changed,
te backlash must be re-set to spec BEFORE checking the contact pattern with bearing blue.
It took me a whole day to get this one sorted.

The next step was to trial assemble the gear stacks and adjust the end clearance of each gear.
I have used the early metal caged bearings throughout:



I drilled holes through the hubs for 1 and 2, and also for 3rd and 4th.





This allows for better oiling of the gear faces under thrust loads.

Here is the first stack trial assembled on the pinion shaft.

Once the end clearances were set and the intermediate housing clearanced for the 1.333 fourth gear,
I scrounged up some missing reverse linkage parts in preparation for the setting of the forks in the jig.





Here you can see the pin that engages the ERCO reverse idler gear:



Steel forks were used for the gear selection, because some are made from a weaker bronze material.

Also the nose cone was machined flat in preparation for the steel thrust plate that helps to retain the main shaft bearing.
Valentino's car has a late model three-bolt nose cone mount,
which actually is the strongest nose cone there is, except less used because it came out on later L bugs.

No Junk there!!!!

Here is the gear set and intermediate housing installed in his case.
Valentino had a salubrious powder coated grey colour for the case, and then polished the ribs.

The nose cone will be done as well after it returns to Sydney.



The clutch fork has been fully welded,
and the long arm is used for less clutch pressure on the pedal.

Well, that last shot showed a peek of those massive side covers.

Them, and the special adapter stubs, are what allows the Swingaxle ZF to be used in an IRS tranny.





There is a support bearing inside the covers,
retained with a couple big circlips.
The taper on the tip is to enable the assembly into the swingaxle fulcrums, sight unseen.
A bit difficult, but it all went together well.

These ones take a Kombi CV joint, and are about 2" shaft size.
No snapping off these suckers.

Ahh! All done!

i guess someone has to ask, sooooooooooo with a user name like mine, here 'tis,

why the swinger ZF only to go irs?

Dave-my jeans are now officially "creamed"-nothing more to say.

Apparently the swinger ZF inside is stronger,
plus no more broken splines at the CV flange.
Better support with the bigger bearing too.

ahh , oh, and very noice as usual........

You mean those output axles are UNBRAKO !!!

Fantastic Dave

valentino the muffler man?

19" wheels Valentino?

Muffler man?
No not 19" wheels.

Mmm, this is a tasty burger!

Jeff should send some of his junk up this way, for a holiday from all those wood shavings.

BAKAHAG is that reversing a old woman? or taking a punt on one.

why does this look like somthing i have seen before.
i think this might be parked in my shop.
i thought it might be some of your handy work involved but wasn't qiuet sure.
we had to make some bracing and other mods.
i will post up some pic's when i get back from fiji.
bula bula.

nisa bula westi! where are the side covers from cant find them anywhere?

Ahhh the missing links.

nice one.bula bula.
i don't know dave i think that loverly grey would be a hard act to follow.and i have never seen side cover's like this before.even the polished high side bit's on the rib's.the other tranny in the shop ,the one which i am yet to update photo's only because i am away that is in a drag car to be,that box was biult by Mr HS 618.
anyhow i will be back next week.photogragh's tell now lies.
cya
P.S more fun=more sun.i have only heard this about 100 times,i thought i might pass it on.

im confused where are the SIDE PLATES from?