I'm finaly getting around to fixing/upgrading trans. This is a side/mid shift vanagon trans. i've got nose cone apart and diff removed and can't get case apart. whats holding me up? seems to something to do with internal shift linkage or should shaft slide out of front bearing?

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

by looking at the shift rods it appears you are going at all wrong, you have to take the pinion nut off (requires a special tool) and knock it apart from the diff side

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Just Stand On It!!!!

Chris

x2

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I DO NOT FREE BASE COCAINE

I've got pinion nut off. it seems like something is hanging up on right hand of case where shift rods are.

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

Replace the short bolt you removed just above shifter assembly hole ,[loosely, just a few threads], shown missing in 1st pic.
Stick finger in shifter assembly hole and pull relay lever outward, screw bolt down til it holds relay lever against case housing, then slide tranny apart.
The relay lever will be just inside shifter hole toward nose of tranny.
That lever is still engaging a shift fork, thus hanging you up.

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A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

Thanks maddog. That did the trick

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

maddog is the man,hehe

How do i get the rest of this mess off the ft half of the case? Also this trans had a horific whine in 3rd and 4th gear. Which bearings should i look at for this noise. Might just replace them all but would like to confirm cause first. I know the pinion nut should be upgraded. What about the cheap looking plastic caged bearings is there an upgrade? Anything else i should upgrade while here? Thanks in advance. Tony

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

Unbolt the shifting forks from the shift rails.
Set it up on something that supports the case.
Use a press on reverse gear or hammer and wood and press the input shaft out of the case.
Most 6 ribs will have a cracked or broken 3rd/4th syncro hub/slider, unless it has already been updated.
Those of you buying 6 ribs [65% plus] that have never been rebuilt will have this problem.
Pinion shaft should easily slide out with it, might have to tap on it a little.
Put that pinion bearing in a vise and check it, by wiggling the pinion shaft. for any play at all.
Input bearing with plastic caged bearing, check for thrust play, in other words will it keep the input shaft from moving in and out.
I usually hand pack 1st gear needle bearings also, the kit from weedle is cheap.
If you should need a new pinion bearing ,I prefer a good used german one from weedle over the new FAG ones from Brazil.
Pinion nut , use the wide flange chromo one from weedle,pain to install but it's the best.
Also as you disassemble the shafts stack it up or lay it all out, so you can reassemble easier.
Also when you're picking up those gears,hubs, etc. looking at them, put them back down facing the same way they were when you picked them up.
It can be very fustrating have to go back and research which way something was supposed to be facing, without a book.
The whinning,remove all gears and check needle bearing under them.
Also, was the pinion nut tight, something doesn't look right on that pinion gear, looks like it was running very shallow, might just be the pic.

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A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

Thank you again! i apreciate all the help! I love to do everything myself. I know exactly what i have that way.
Somebody has been in here before if even just for the diff. They had marked the diff flange nut positions. They were also INCREDIBLY tight!!! How tight should they be?

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

they problay shouldnt be as tight as u say they was,could had been some of ur noise

For offroad use, I generally get the backlash right, then tighten the screw-in bells enough so everthing is bottomed out good.
If you get too agressive you can eggshape the case.
After you get the bellhousing bolted on then give the bell on the side pushing the ring toward the pinion an extra 1/16 or less of a turn in.
You know, just to make sure it's tight.

_________________
A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

I have everything apart except pinion bearings. Thats a nut i assume that threads off? all my bearings look ok that i have apart but one of the pinion bearing sounds rough. already broke the pinion race assembly/carrier or whatever you call it so its got to come apart now. I did'nt have it in press quite right when getting gears off and broke the ledge thats around it.

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

yep,funny lookin nut

A pipe wrench will work on the smaller inside pinion nut, just be careful not to mess it up.
Then find something that will catch the inside most part of the pinion bearing race, to hold it while you press the bearing off the pinion shaft .
I use a bearing separator from harbor freight $40 to hold the pinion race in the press.

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A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

Is that pinion nut right or left hand thread? It won't budge!

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

Lefty loosey. I have lightly heated them before, just don't unharden it.
Try a punch to persuade it 1st, just be careful.

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A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

Anybody on here made a wrench for that smaller inside pinion nut?
I need a idea on how to fabricate one.

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A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

i think this is the tool you talking about



the big part clamps in a bench vise and holds the nut and you slide the splined/nut looking part of the tool on the pinion shaft and actually use it to turn the shaft and the funky nut is held stationary

the pic is from a friend of mine who bought the tool so it is not home made but maybe it will you an idea

_________________
Just Stand On It!!!!

Chris

any idea who makes it or cost?

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

Weddle has it.
The factory pinion holding fixture & hex piece for the small 091 pinion nut is part # 7-2052 $263.20 .
I think that is the one pictured above.
That price is from a 2009 catalogue.

_________________
A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

This is a copy and paste of Bruce2's post from shop talk forums.
I'm probably gonna do something similar.

From Bruce2
Here's the tool I made:

http://www.flickr.com/photos/22746410@N00/3320506461/in/photostream/

I took a piece of 3/8" bar stock and scribed a circle on it. Then I drilled a bunch of holes on that circle. Cut out the center. Drill a ½" hole off to one side, then file the corners square.

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A good friend will bail you out of jail. A best friend will be sitting next to you saying: "Damn that was fun!"



http://www.youtube.com/watch?v=A5wGMaUMXUQ

Just a follow help and again thanks for all the help. 1 of the pinion bearings is very noisy just spinning by hand. I'm sure that was my noise and all else looks ok. Whoever was in here before over tourqed everything. I never got that nut off of the pinion shaft! It became kind of a game. I have had the nut RED hot and the shaft in a vice and it will not move!!! I wanted steeper gearing anyway so i'm going to get another ring and pinion. No real choice at this point. I'm saving the bucks now. Good thing i have a spare trans.

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.

have you tried to cut it off with a dremel or other rotory tool and abrasive wheel?

_________________
Just Stand On It!!!!

Chris

Thats about the only thing i did'nt do. I'm going to get a steeper ring n pinion set. I have reason to spend the money now and i needed new pinion bearings anyway. Better gearing and a superdiff. yay!

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Turbocharged Ecotec,vanogon midshift,Berrien WoodsBuggy wagon.