Hi I'm Sam with
JBugs.com. With the disc brake conversion complete and our suspension lowered, we
will address some other issues on our 1963 Resto Custom Beetle.
The transmission mounts
in the car are separated and will have to be replaced. We'll pull the
transmission out and while it's out were going to clearance it for a larger 12
volt flywheel. This would have been a lot easier to do when the pedal assembly
was out or while we were lowering the rear end of the car. We realize you all
at home may not be able to completely tear apart the rear end of your car, just
to remove the transmission.
Keeping that in mind we
get started with the front wheels chocked and loosen the lug bolts on both rear
wheels. The rear end of the car is jacked up and set on jack stands underneath
the torsion housing. The rear wheels are removed so that we can access the
brake and suspension components. The axle nut cotter pin is removed and an axle
nut removal tool is bolted to the rotor so the axle nuts can be removed.
Inside the car, the
parking brake cables are loosened and back at the rear of the car the cable cir-clips
are pulled and the cables are removed from the brake calipers. Next, the
caliper is unbolted from the bracket and the brake hose clip is pulled from the
axle tube so the caliper and line can be removed clear of the axle without
disconnecting a brake hose or line.
With the caliper
removed, the brake rotor can be pulled off the axle. This process will be
similar for drum brakes, with the drum coming off first followed by the brake
cable. The backing plate can be removed from the axle allowing the wheel
cylinder [to] remain attached to the brake line so it doesn't have to be bled
later. The lower shock nut is un-threaded and the shock is pulled off the mount
on the transmission axle. The axle is unbolted from the spring plate, the bump
stop and plate are set to the side.
The same steps are taken
on both sides of the car. Inside the bell housing the rear mounts are unbolted from
the transmission and rear cross member. The clutch cable is loosened from the
clutch arm while making sure to keep tension on the clutch cable. If the cable
gets too lose, there's a chance it could fall off the pedal hook and then the
pedal assembly would have to come out.
Next, the front
transmission mount is unbolted from the chassis. Underneath the rear seat
inside car the shift coupler access plate is unscrewed, to access the shift
coupler which needs to be disconnected from the transmission. After the safety
wire has been cut, the two coupler screws are un-threaded and the shift rod is
pulled from the coupler, then the coupler is pulled off from the transmission. The
transmission can now be removed from the chassis by sliding the transmission
back so the nose cone and gear selector are clear of the chassis.
A jack is used to raise
the transmission up so it can be slid back further until the axles are clear of
the rear mount. Now the jack can be re-positioned and used to lower the
transmission back down to the ground. With the transmission out and on the
floor the nose cone boot, mount, and ground strap are all removed.
The bell housing will be
ground down so that we can fit a later model 12 volt flywheel. The transmission case is
made of magnesium and magnesium fires are nearly impossible to extinguish. Extreme
caution must be used. Make sure there is no steel in the area being ground as a
spark could ignite the shavings. We use a small air powered angle grinder to
remove material from the four engine bolt bosses so that we can mock up the new
We use a flywheel
mounted to a crankshaft along with the clutch disc and pressure plate to show
why the transmission must be ground. [We] use the assembly to indicate where
the transmission needs to be ground down. The flywheel is installed into the
transmission input shaft and spun a few times then pulled out. We can see where
the flywheel is touching and grind the areas down. The process is repeated
until the flywheel installs and spins without contacting the transmission.
To finish, the original
six volt starter bushing is removed using a chisel and a hammer. The
transmission will be cleaned up, in our next video we'll cover installing new
swing ale boots then we'll reinstall the transmission using new stock
replacement mounts and we'll be adding a new transmission strap kit to help
hold things in place. Stay tuned and in the meantime head over to JBugs.com for
all your Volkswagen transmission parts and accessories.