Good write up on transaxle tear down and rebuild on SAMBA with lots of great photos. Wow - what a lot of parts to keep track of.
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I was thinking of making some helpful comments on there, but Al's friend Bruce is on it. This will certainly be a good reference. I've got the Long Enterprises(now defunct) rebuild CD. I've got a Bentley manual, spare parts(extra transmissions), and a really detailed plain-language book by Casting Timmy(from thesamba).
Plus I've done a few rebuilds. If I can do it, you can. You just have to set your mind to it.
Transmissions really aren't that hard. They are definitely easier than motors. You do need a press and a few special tools(that aren't cheap) but the transaxle is pretty straightforward. The biggest problem is a jig(or cut up trans case) to set the shift forks.
The thing that has always kept me from cracking a transmission are the tolerances you have to get right.
I never felt like I had the right measuring tools. Engines seemed easy by comparison. Hats off to you, Danny!
@Michael Pickett posted:Engines seemed easy by comparison.
You can say that again. I don't have it in me - they're magic boxes. I know what gears I want, but have zero knowledge of how to make it all play nicely.
Lots of folks make transmissions sound more complicated than they are.
Take LOTS of pictures while the shafts are together and especially as you take it apart.
RE: the trans that is the subject of the link:
It amazes me that some yahoo put it together and the two nuts that need serious torque were hand tight, and there really wasn't much damage. The pinion bearing nut needs 160 ft. lbs. to keep the shaft together! The large nut to keep the bearing in the case is pretty important too, that keeps the ring and pinion in tolerance. I'm truly surprised that trans didn't explode, but it did have stock power, so...