Adam,

Could you please send me the link to your Mount repair post, I wouldn't mine having a read of it my self.
Cheers ,
Frank

 

Thats great, thanks.
How much of the transmission did you have to remove/drop.
I take it once the transmission mount is unbolted from the car it drops on a Jack enough to remove the mount completely.
Frank.

 

Well I put everything together today. Torqued everything down as per Mikey's specs. I put blue loctite on all the bolts to make sure nothing backs out and a bit of silicone sealer on the tube connecting the tranny case to the transfer case.

I wanted to take it for a test drive real bad, and I stayed up till 4AM working on it, but apparently more fluid came out than I thought and the 4 quarts I bought weren't enough. I didn't want to drive it like that so I just ran it through all the gears on the lift and called it a night. Also looks like 5.* Durametric doesn't give you the temp for the trans. I wonder if the 6.0beta does?

 

I'm eager to hear whether you've fixed the whine. I'm bringing my car in to the dealer monday to have a look at the mount and the play in the shaft ... I imagine the work you've done would be $$$ at dealer or even indy rates.

 

great work adam!

 

Well, the whine is back. Less than 300 miles into it.

Before I tear into it it would whine at about 40 mph.
When is started to whine again t would do so at 50mph and than slowly got worse down to 40 again so I assume it's the same thing.

The good news thou is that there is no leaks!! so I'll be using the same gaskets for round 2.

I honestly think it's my fault that the whine is back as after double checking everything I realized that the LOCTITE compound I used on the bearing asked for 24 hours setting time for maximum strength and I only gave it 6.

Well with take 2 there can be no more screw-ups. I'm sure bu not I can take it all apart in 30 minutes,,,,but I really enjoy the car more when I can drive it...


So for take 2 I've done some more research into the subject of how can this be fixed....

I've consulted with my buddy who is a CNC expert and works for a company who makes joints for Flaming River....you hot rod guys know them for their steering joints/racks.

He called his other buddy who owns a machine shop and we have a plan on the table.

A major break through occurred when I came across this website when goggling the internet:

http://www.usatolerancerings.com/repair.html

Well the plan is to do exactly what it says

So I will keep you tippy guys updated as it goes

 

Sorry to hear this Adam but good luck with the repair and keep up the good work!

 

$hit Adam, thats a Bummer....sorry to hear this. Lets hope it works this time.
Frank

 

Well, I started tearing into it today.

Doesn't look like a total failure...as there is no sign of leakage, so the gaskets I made are holding up just fine.

I wrecked the new seal ($5) as there was no way to keep it intact and I wanted to inspect the Seager Ring that retains the bearing and to see if there is any evidence that the bearing is spinning. Good thing is that I documented everything very thoroughly with pictures so I can compare if it looks shifted looking at the markings on the bearing race.(I'm heading to the garage to do that now and I'll report)

One thing that I did this time around that saved me a bunch of cleanup is that before I started taking things apart I drained about a gallon/4-5 liters from the tippy into a clean bucket through the drain plug on the bottom of the pan. I definitely recommend doing that as it will allow me to reuse the fluid after I filter it.

 

Well, I took the seal out. Compared the bearing to the pics I've taken before. I even took the Seager ring out to see if it has any marks and NADA. That bearing is not going anywhere so I guess I didn't fail with my FIX.

The bad part is, something else is whining and now I'm again on a mission to find out what

 

Good luck Adam with getting it working!!

 

Well, I'm tearing it open again.

I had a breakthrough today as my primary suspect for the noise-making is this little bearing that I couldn't find anywhere as it is only made to order by INA for the manufacturer in 10000s quantity.



After months of searching on the NET and many phonecalls.....many.... I think I found it....in russia....well actually that's where I found the cross reference info and just ordered it from VW...go figure!!! So, now I'm going to take it all apart again as I almost lost hope in finding that PITA bearing...I guess persistence pays off. I was actually contemplating converting that trans permanently to rear wheel drive only, but I really like the AWD since I live in the rust belt.

 

Well done Adam,
Were all watching you progress.
Frank.

 

Just finished taking it apart. I'm getting better at this....I really don't want to do this again anytime soon.

Now my dilema is if I should yank all the bearings out and replace them or only do the one that I think is faulty.... If I had the specs/tolerances for this thing it would be easy but without it I really don't want to screw it up more than it already is.

 

So today, after months of searching, a failed order through VW NA and a lost package through Ireland Post......it finally showed up ob my doorstep!!! Yes the tiny bearing is here.



Please guys keep your fingers crossed. I'm attempting to put this beast together today again. Hopefully everything goes smooth.