DUBSTAR'S PROJECT - Weiss Hase - 1976 Golf LS

[sports racer]

Great score on the motor, should provide "more than adequate" performance.

That's how Rolls Royce used to quote the power figures for their V8's.

[dubstar]

So it's been a while. I have decided to give the 020 rebuild a go. I have basically printed off the entire BrokeVW rebuild instructions and am using them as my guide.

I started by making up some of the tools required using various steel off cuts. The first pic shows the input shaft support bar, the second shows the shift fork release tool.







I also got a nice shiny new press for my Birthday

I have removed the 5th cover and shift forks, but my old pullers are too 'fat' to fit under the gear set. I've ordered a new puller set, so will crack in when that arrives

[sports racer]

You're a brave man for tackling a gearbox rebuild.

I'd be worried that when I take the case apart a small piece goes "twang" as it exits the gearbox at 1000 mph and disappears forever.

[dubstar]

So, I got a few hours in today.

I used my homebuilt case splitter to split the case







The internals look pretty good. A few little marks, but no missing teeth (in my initial inspection). The downside is that the diff is still riveted, not bolted.

Now I need to decide what parts I will replace. Bearings, gaskets, etc, etc….any expert thoughts or should I just replace the low?

[Water Boy]

Get rid of the rivets for the bolt kit!

[dubstar]

Turns out those aren't rivets, they are just the back of the studs from the bolt kit. The transmission looks good, so will button it back up

[roccodingo]

Someone has been in here before ( replaced rivets )

Wash out everything, check the syncro side clearances and see if they are kaput. If not then replace all seals, clean the magnet. and re assemble.

Looks like it had a case gasket ?? make sure you put a new one in on assembly . I ditch the gaskets and use the VW sealant on the case halves, but you need to check the bearing preloads and adjust accordingly if you go this way.

Good luck.

[dubstar]

No gasket. It was assembled with sealant, so that's what I will use too. Brian at BrokeVW has sorted me out with everything I need

[dubstar]

DUBSTAR'S PROJECT - Weiss Hase - 1976 Golf LS

Quick update, if you can call it that.

The gearbox is all together now and I am now finishing off the engine. A few bits to go. The DHLA's are all overhauled and ready to go on the manifold, which just needs some porting

[browndizzle]

So so clean and mint

[browndizzle]

Mind doing my interior for me too? Looks beautiful!

[dubstar]

Its been a crazy few months with multiple trips for work, but I finally got to do a little bit of work on Andy. This is in preparation to finally getting my nice shiny new engine into its new home.

I am using a Carter fuel pump for the DHLAs and I wanted to wire it up using an OEM Mk1 GTI fuel pump relay to give me the safety cut off feature. I used an OEM relay plate and then ran the wiring in OEM plastic sleeving.

It works and came out looking quite OEM (except the actual pump), which is good









Next step is to remove the old lump (anyone have an engine crane I can borrow for a weekend?)......

[MarcusAurelius]

I got a crane and stand you can use buddy. I'm in Narre Warren

Sent from my SM-G900I using Tapatalk

[sports racer]

Nice setup.

[Volksee77]

mate that looks awesome. where did you find the factory relay plate? I need to do the same for mine.