Tranny Transplant
 
I have the need...the need for speed...
 
Before I continue on, let me start by saying, “I ain’t no expert!”  While this isn’t grammatically correct, it does convey the reality that while I am not an idiot, I do not possess the experience to do a lot of the work on my VWs without the aid of friends, reading books, and a lot of research on the Internet.  Since I was looking at replacing the engine in my Westy anyway and after several discussions on the Type2 and local VW club, CAVWC, email list, it was suggested that I might want to swap out the 3-rib transmission that came with my 71 Westy with a 6-rib out of a 1976 or later bus.  The swap, theoretically would give me a better “top end” allowing me to go a little faster at highway speeds with less strain to the traditional upright Type-1 motor that the Westy would have.  Overall the thoughts were with the upgrade in engine from the stock 1600 cc to the now 1776 cc, I would get a little more power and with the tranny swap I would get a little more speed.
 
Then it dawned on me, I had a 1976 bus out back that needed a motor rebuild.  Did it have the 6-rib tranny I needed?  After crawling under, I found out I was in luck. (see left)  I then proceeded to pull the two transmissions.
 
Now this part sounds easy, right?  You would think you would just remove the bolts holding the front transmission mount, remove the the grounding strap, and detach the axels going to the CV joints and you would be done.  Well, things are never as easy as they first appear.  While it is true, we are dealing with two different types of transmissions here. We are also dealing with some subtle differences.  The primary differences you will see with the “naked eye” will be a different front transmission mount.  But this won’t be a big deal and it is easy enough to deal with (we’ll discuss this later)  However, (unless your eyes are better than mine) what you probably won’t notice is that both axles may have different types of bolts holding them on to the tranny and the wheel hub at the CV joints.  One set of bolts could be a 6 mm hex or “allen head” bolt (these seems to be typical).  If you have these, you probably own an allen wrench or a allen/hex socket that will do the trick (even though the holes are sometimes worked out over time to be more like 6.5 mm and you may end up using a 7 mm or even a standard measure hex/allen to get them out).  BUT, you may also run into what I have heard referred to as an 8 mm 12-point “triple square” bolt.  If you do, as I did, run into these bolts, DO NOT try to use the aforementioned hex/allen tool.  You will only strip out the bolt and begin using those explicatives that you don’t want young ears to hear.  If you find these types of bolts, go ahead and spend the few bucks and buy the proper tool (see right).  My tool looked a bit different but as the saying goes, “the right tool, for the right job makes all the difference”.
 
After you removed the two trannies, you will see some differences (some I mentioned earlier).  The main difference you will have to deal with next is the input shaft.  The input shaft carries the power from the engine into the tranny and is longer on the later model 6-rib transmission than the 3-rib.  Also, the bell-housings differ because of the starter differences between years.  I wanted to use the earlier model starter (they are easier to find and what was actually made to mate up to my motor) so I opted to swap out the bell-housings.  As far as the input shaft goes, I had a decision to make...  Some say, “just cut a little off the shaft and it will work fine”.  Others state you really should swap them out.  I chose to do the later, swap out the input shafts, but let me say, “It is tricker than you would think”.
 
So, drain the gear oil and remove the bell housing (just a few bolts).  Now, as you look down into the “bowels” of the transmission, once the bell housing is removed, you see a collection of gears along with this, now infamous, input shaft.  This shaft is actually screwed on and is held in place by a circlip (or C-clip).  In order to remove the input shaft, you must...
 
  1.   Remove the C-Clip
  2.   Slide the gear on the input shaft forward
  3.   Unscrew the old input shaft
  4.   Remove the input shaft and the gear
  5.   Place the old gear on the new input shaft
  6.   Screw the new input shaft in place
  7.   Then, slightly unscrew the new input shaft (half turn)
  8.   Slide the gear back into place
  9.   Replace the C-Clip (preferably with a new C-Clip)
 
And, you must do this twice so that you have the input shafts from both transmissions in order to swap them.  Sounds easy right?  Well, before you start, make sure no young impressionable ears are within “ear shot” and then begin.
 
 
 
Winter 2007 -2008
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