What You Need to Know about Rebuilt VW Transmissions

The Scoop on Rebuilt VW Transmissions

We caught up with Tony Walker of Aircooled Werks to talk transmissions. Guy knows his stuff, which is why we love using his custom-built transmissions in our builds. If you're in the market for a rebuilt transmission or transaxle, here's what you should know.

Rebuilding quality VW transmissions and transaxles takes the proper knowledge and factory tools to get the job completed. A rebuild starts by updating your gearbox with many new VW components instead of using used parts from other gearboxes to make something work. VW did a wonderful job engineering these gearboxes 40+ years ago with many modifications through the years. For the best results, make sure your transmission builder updates your unit with only the best and latest VW parts.

Tony starts with updating the gear carrier by re-bushing the 1^st/2^nd and 3^rd/4^th shift rails so you have smooth shifting without future problems.

This solves another problem - one of popping out of 4^th gear. The factory 3^rd/4^th slider was only flank cut on the 4^th gear side and only on one side of the tooth. We install a new 3^rd/4^th slider that has been cut on all four flanks with better angles to enhance shifting. This allows the slider to fully engage the gear synchronizer hub and hold it in gear.

Reverse gears are often abused and then become a problem. We replace all reverse gears.

The 1^st/2^nd gear sliders are also replaced. They are flank cut on all four sides for better slider/synchronizer hub engagement.

We replace both 1^st/2^nd and 3^rd/4^th shift forks with new steel 5mm late models.

Media blasting is a vital part of the rebuild. We make sure all the reusable parts are thoroughly cleaned and inspected before being reinstalled.

Nose cones are vital to the transmission shifting correctly. Used and worn, they can allow differences that put pressure on the hockey stick and shift rails. We install new nose cones to alleviate any problems.

One of the most overlooked areas on a rebuild is the clutch cross shaft. VW only spot welded the arms from the factory. We take the best original shafts and weld both arms for better strength, or if needed, we install an HD shaft for maximum strength.

After all parts are cleaned, blasted and replaced, their respect shafts are then assembled with new synchronizer rings and placed into our German shift jig.

We make sure the shift points for 1^st/2^nd gear and 3^rd/4^th gear are set for proper and smooth shifting, as well as reverse gear alignment on the 1^st/2^nd gear slider.

We feel these modifications give you the best and most reliable VW transmission and transaxle money can buy.

If you're in the market for a rebuilt VW transmission for your ride, contact us for more details about how you can get one just like this.