Club 80-90 Forums

Hi. I'm rebuilding my 2.0 Aircooled CU engine, but whilst I'm doing it I've also dropped the gearbox to give it a little attention (On a budget).



I'm planning to give it
* A good jet washing (After ensuring the input holes are covered!)
* New output shaft seals
* New input shaft seal (How do you get the old one out? Justa case of digging about?)
* Fresh oil

It's pretty high milage and I bought the Wedge as a non runner so havn't driven the gearbox. I havn't got much cash available, but is it worth splitting the case to check for wear? The gearbox oil was pretty clean on removal. I've worked on mini gearboxes before but have never split one of these. Maybe worth replacing the synchros?

Is there a good place to get new seals and the plastic 'toothed' output caps too?

brickwerks for the seals and adjusting ring covers
take the bellhousing off to change the oil seal it's much easier and you can check the crown and pinion and measure the backlash, otherwise read the procedure in the bentley manual and decide if you fancy having a go without the specialist tools - it can be done with a blunt instrument and bravado but results are not always good

Hi Aiden, thanks for the info. Found all the bits on Brickwerks ok for about £20 (Including a bellhousing gasket). Nice one

Bentley manual? Is that a nickname for the Haynes or something else entirely?

Is there anyone who sells diff re-build kits or has a good selection of other gearbox gubbins (That I hopefully won't need anyway)? I'll pop off the bell housing like you advised. At least I'll then have a good idea of the overall wear levels in the box I suppose!

the robert bentley manual is the big thick manual about 50 quid well worth investing in if your into these vans

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Just a bit of an update...

I've removed the output pots and bearing seals.



The gearbox it absolutely caked in ming so I got scraping and managed to get a good pile of muck off of it!



I got this far before having the inspirational idea of popping it down to the steam cleaner car wash nearby on Dixon street to see what they could do.



After speaking to the 'Eastern European guy' working that day he said it'd be fine and set to doing each side with his industrial steam cleaner. It ended up like this.



It's not show winning but much much tidier. Especially considering it only cost me £2! Much better than getting in the "pooh" with the missus for putting it in the dishwasher! I popped the bellhousing off to assist getting the input seal off and also to inspect for any nastyness or chunks of metal floating about. All clear and diff seems in good nick too. Good job as I can't afford a rebuild!



That's updated for now. Next will be the new seals, gaskets and oil and she'll be ready to go back in. Cheers for the hints!..