Gear box rebuild manual

[flying haggis]

Hi all,im after a manual for rebuilding the gear box in my bus,I'm doing a aaz conversion as I bought it as a none runner and thought id change the gear oil and stuff when the box was out.I've drained the oil only to find the syncromesh key things stuck to the drain plug.So im wondering if anyone has a gearbox manual or a bently vanagon manual I could borrow or buy.
Also does anyone know if a 2.0 Aircooled box would fit I know the selescor shaft or somthing needs modded but what about ratios etc im new to t3 so any help would be ace.
cheers

P S Happy new year

[Oldiebut goodie]

Become a member, then go to:
https://club8090.co.uk/forum/viewtopic.php?f=7&t=110469
for manual download.

[flying haggis]

Just joined,spot on thanks

[California Dreamin]

Hi all,im after a manual for rebuilding the gear box in my bus,I'm doing a aaz conversion as I bought it as a none runner and thought id change the gear oil and stuff when the box was out.I've drained the oil only to find the syncromesh key things stuck to the drain plug.So im wondering if anyone has a gearbox manual or a bently vanagon manual I could borrow or buy.
Also does anyone know if a 2.0 Aircooled box would fit I know the selescor shaft or somthing needs modded but what about ratios etc im new to t3 so any help would be ace.
cheers

P S Happy new year

A 2.0L Aircooled box won't fit.

Ideally you need a taller final drive ratio to go with the stronger AAZ.....
I'm not saying rebuilding the box yourself isn't possible but it does involve several 'special VW tools' so even those in the trade tend tp leave these to someone in the know.
We do have a resident gearbox expert (Aidan Talbot) quite frankly I wouldn't trust anyone else.

Martin

[Aidan]

OP and I have spoken, it was me that said (given op's skill level), take a look at the manual and see for yourself if you fancy doing it, if you do I'll supply the parts
On average I probably give the same advice to 6-10 people a year who call me, most don't do it themselves but I wouldn't discourage anyone from having a go, armed with the procedure and with due consideration, it's how I started
OP is in John O Groats, not exactly handy for getting box to and from me for rebuild, the transport costs alone would pay for most of the bearings for a full rebuild
AAZ is fine on standard TD gearing, but can pull a bit longer, but 7/32 final drive boxes are getting thin on the ground used as fewer T3s are broken and peeps often asking silly money for what are basically cores for rebuilding in reality just because it's an AAP

[camper]

A 2ltr cu DK code gearbox will fit to a AAZ provided the bell housing &input shaft is changed for a diesel gear box one.The only problem is the gear selection rods the DK code gearbox rods may be diffrent to your existing onces .Very early year models where fitted with 1.6 ct /2ltrcu DK code gear selection rods which would make it simplier .I did a 1Y 1.9 diesel conversion to 2ltr cu DK gearbox and fitted the DK gearbox selection rods so no the problem.

[California Dreamin]

I hadn't realised flying haggis had spoken to you Aidan....

I'm all for having a go....if there are work arounds (special tools)

Martin

[weldore]

Ive a dk on my 1y too..a bit of creativity with the nose mount and the gear stick rods needed but very doable