Sterling #S009
- Thread starter Brett Proctor
- Start date
Brett Proctor
Well-known member
Thanks*thumbs up*
letterman7
Honorary Admin
Looks great Brett! Sorry I hadn't been around; I took off for a week vacation with no internet and no cell! But yeah, great fabrication on that lower mount. Most guys will mount the end of the ram wherever it seems to fall, whether it's on the sidewall or the bottom of the little cutout. I don't recall how the cars were built specifically - there was a chopper gun I'm sure, but I wouldn't rule out hand laying the early bodies to get a "feel" for how fast they could be produced.
Don't blame CCC for the inconsistent bodylines - they were all pulled from a Nova mold. Blame the Brits on this one!
Don't blame CCC for the inconsistent bodylines - they were all pulled from a Nova mold. Blame the Brits on this one!
Brett Proctor
Well-known member
I was wondering why you were being quiet Rick.
I can usually count on you for honest input
You wont cut me no slack.
Thanks
Brett
I can usually count on you for honest input
You wont cut me no slack.
Thanks
Brett
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Brett Proctor
Well-known member
Been working on the transaxle. Finally got the super diff in today along with the rest of the parts I needed. I changed out the 4.12:1 ring and pinion to a 3.88:1 and tomorrow I'll work on getting that set up right. Changed out some worn out bearings, installed a new input shaft, replaced all seals, put new syncros in and basically replaced anything that was worn or out of specs. All so I'm changing over to type 2 CV's so I got the new flanges for that. Hopefully The transaxle will be done by the end of the week and I can install it.
Brett
Brett
letterman7
Honorary Admin
Nice *thumbs up* ! Sounds like you know your way around mechanical components, Brett. I'd be scared to death to dive into a transaxle with all the tolerances that need to be kept!
Brett Proctor
Well-known member
I started setting up the super diff yesterday and encountered a few problems that I thought would be good info for those thinking of putting one of these in.
First off it really ticks me off when a place shows a picture of something and thats not what you get. Case in point the super diff. The one I got will fit a type1 transaxle but its not what they had a picture of. The picture showed a nice machined piece of steel. The one I got was a ugly cast piece made in china. I have never had any luck with china crap. The housing has no provisions for oil getting inside like the stock one does. The picture that was posted for the diff did. So now I guess I get to mill some oil holes into the caseing.
Another fine point is that it came with no instructions. None. Zero. So I'm using the factory manual to set it up. OK here's where it gets to be real fun. The method to shim up the differential gears is to add additional thrust washers. Well they only come in one thickness(.5mm). A trip down to the trany shop to find out how they do it didn't make me feel any better. I was told to sand down the thrust washer to the desired thickness??!! Are you kidding me I asked. The guy said thats what they do. Well thats not what I do. I have shim material so I made my own shims.
By adjusting the play this way your pulling the differential gears into the housing. Not happy with that but what are you going to do. VW used a different method that didn't pull the gears into the housing. I don't see why they didn't do it that way.
OK lets get to the spider gears another china piece of crap. Casting was very poor. I couldn't set the tolerances to factory specs because the gears were so poorly cast that when I did shim it up to factory specs the diff wouldn't turn. Factory called out for 0 to 0.005" (thats 0 to .14mm for our metric friends) end play. I had to set it up to 0.008" and it still isn't smooth because of the high and low spots on the spider gears.
For over $200 I expect alot better quality than what I got. Not happy with it
Well thats how its going. Today I'll drill the holes in the housing(for oil) and hopefully get it together
Brett
First off it really ticks me off when a place shows a picture of something and thats not what you get. Case in point the super diff. The one I got will fit a type1 transaxle but its not what they had a picture of. The picture showed a nice machined piece of steel. The one I got was a ugly cast piece made in china. I have never had any luck with china crap. The housing has no provisions for oil getting inside like the stock one does. The picture that was posted for the diff did. So now I guess I get to mill some oil holes into the caseing.
Another fine point is that it came with no instructions. None. Zero. So I'm using the factory manual to set it up. OK here's where it gets to be real fun. The method to shim up the differential gears is to add additional thrust washers. Well they only come in one thickness(.5mm). A trip down to the trany shop to find out how they do it didn't make me feel any better. I was told to sand down the thrust washer to the desired thickness??!! Are you kidding me I asked. The guy said thats what they do. Well thats not what I do. I have shim material so I made my own shims.
By adjusting the play this way your pulling the differential gears into the housing. Not happy with that but what are you going to do. VW used a different method that didn't pull the gears into the housing. I don't see why they didn't do it that way.
OK lets get to the spider gears another china piece of crap. Casting was very poor. I couldn't set the tolerances to factory specs because the gears were so poorly cast that when I did shim it up to factory specs the diff wouldn't turn. Factory called out for 0 to 0.005" (thats 0 to .14mm for our metric friends) end play. I had to set it up to 0.008" and it still isn't smooth because of the high and low spots on the spider gears.
For over $200 I expect alot better quality than what I got. Not happy with it
Well thats how its going. Today I'll drill the holes in the housing(for oil) and hopefully get it together
Brett
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letterman7
Honorary Admin
Oh... not good. Would you hint at where you purchased the unit so that everyone can be made aware? Have you contacted them about the contradiction between the photo and the actual unit you received? Personally, I would have sent it straight back; I don't trust cast Chinese junk for anything critical, especially a differential unit.
Brett Proctor
Well-known member
That's just wrong.
It's a shame that they get away with stuff like that.
Have you looked at Aircooled.net???
They have them listed as MADE IN USA
$210 for IRS
$170 for SA
No picture, but you could call them and they might even send you a picture.
Aircooled.Net, Inc. - Online Autoparts Catalog
Edit - I forgot you plan to make due with what you got and already started modifying it...
It's a shame that they get away with stuff like that.
Have you looked at Aircooled.net???
They have them listed as MADE IN USA
$210 for IRS
$170 for SA
No picture, but you could call them and they might even send you a picture.
Aircooled.Net, Inc. - Online Autoparts Catalog
Edit - I forgot you plan to make due with what you got and already started modifying it...
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Brett Proctor
Well-known member
Aircooled.net has pissed me off three times on screwed up orders that was their fault so I don't deal with them any more.
Got the differential together but didn't drill the holes(when in dought leave it alone). I wasn't sure why they didn't cast any holes for oil so I left it alone.
Talked to a guy at long enterprise named rick about setting up the trans and this guy knows his shit. He was calling out part numbers like it was nothing. They rent out tools for the trany so you don't have to buy them and was more than helpfull talking to him on the phone. I'm sure I sounded like an idiot to him but he hung in there and gave me a leason and history on VW transaxles. I learned alot more from him than the trany shop here in town.
Any way I rented a tool from him and got the parts I was looking for. Great guy to deal with. The web site doesn't have an order on line site because of all the different versions and year changes to the transaxles and he wants to make sure you get the right part so you have to call to place an order.
Well thats it for now
Brett
Got the differential together but didn't drill the holes(when in dought leave it alone). I wasn't sure why they didn't cast any holes for oil so I left it alone.
Talked to a guy at long enterprise named rick about setting up the trans and this guy knows his shit. He was calling out part numbers like it was nothing. They rent out tools for the trany so you don't have to buy them and was more than helpfull talking to him on the phone. I'm sure I sounded like an idiot to him but he hung in there and gave me a leason and history on VW transaxles. I learned alot more from him than the trany shop here in town.
Any way I rented a tool from him and got the parts I was looking for. Great guy to deal with. The web site doesn't have an order on line site because of all the different versions and year changes to the transaxles and he wants to make sure you get the right part so you have to call to place an order.
Well thats it for now
Brett
letterman7
Honorary Admin
True, but damn, even the spider gear carrier isn't the same as the ad. There's no excuse for that. I'd seriously call and talk to someone high up at whatever company you bought those from and make a case, even as far as reporting it to the BBB (not that it would do any good) for false advertisement.
Brett Proctor
Well-known member
I don't have the time to send it back. The tool I rented will be here tomorrow and I'll only have it for three weeks to set up the transaxle. I guess I could order one from some where else while I send this back but Then I'll have to undo everything I've done(remove the ring gear The shims), then to shim up the new diff(remember I had to make my own shims and that takes time) and install the ring gear . I'm not going to be rushed on this.
Plus I'll get stuck with shipping on the returned one. and it will have marks on it from the ring gear being pressed on so they will probably not refund the full amount.
My main worry is if the diff will get lubed enough so it wont seize up on me. Not happy at all*very frustrated**freaking out mad*
Went through this with aircooled.net. I'll make due with this and pray it will stay together.
That company just lost a customer. The name of the company was Mooreparts.com
Plus I'll get stuck with shipping on the returned one. and it will have marks on it from the ring gear being pressed on so they will probably not refund the full amount.
My main worry is if the diff will get lubed enough so it wont seize up on me. Not happy at all*very frustrated**freaking out mad*
Went through this with aircooled.net. I'll make due with this and pray it will stay together.
That company just lost a customer. The name of the company was Mooreparts.com
Brett Proctor
Well-known member
The order came in today from Long Enterprise. Now that was fast. All the parts were the right ones and they sent me the tools needed for setting up the trany so I got started setting up the ring and pinion.
I finished that and started the install of the gears only to find out that the local shop here in town sold me the wrong shifting fork for first and second(I brought my old one down for them to match up and they still got it wrong). So that ended the day. Tomorrow I'll head down to the shop and see if the have one that fits.
Brett
I finished that and started the install of the gears only to find out that the local shop here in town sold me the wrong shifting fork for first and second(I brought my old one down for them to match up and they still got it wrong). So that ended the day. Tomorrow I'll head down to the shop and see if the have one that fits.
Brett
ydeardorff
New member
Damn the Luck!
Your starting the take after me!*laugh*
Your starting the take after me!*laugh*
Brett Proctor
Well-known member
Despite all the set backs the transaxle is together and ready to be installed. Now if it will just stay together when I get a motor for it. Time will tell
If anyone is planning to do this I highly recommend getting the transaxle rebuild CD from long enterprise. It has info that the bentley manual doesn't cover and is relative to the rebuild(both swing and IRS).
I think the most time consuming was shimming up the ring and pinion and after that the shimming of the drive covers because one effects the other. There is a special tool for that but I didn't have it so I resorted to the old way of trial and error untill I got it within specs. This doesn't need to be done if you keep your existing ring and pinion but I changed mine out.
Tomorrow the transaxle will go in and I still need to buy the bus CV's and related hardware (converted from type 1 to type 2)before I can hook up the drive shafts.
Money is starting to become an issue(christmas and 3 birthdays. I get hit hard this time of the year) so I scraped the buying of wheels right now and I'm looking at priorities.
Brett
If anyone is planning to do this I highly recommend getting the transaxle rebuild CD from long enterprise. It has info that the bentley manual doesn't cover and is relative to the rebuild(both swing and IRS).
I think the most time consuming was shimming up the ring and pinion and after that the shimming of the drive covers because one effects the other. There is a special tool for that but I didn't have it so I resorted to the old way of trial and error untill I got it within specs. This doesn't need to be done if you keep your existing ring and pinion but I changed mine out.
Tomorrow the transaxle will go in and I still need to buy the bus CV's and related hardware (converted from type 1 to type 2)before I can hook up the drive shafts.
Money is starting to become an issue(christmas and 3 birthdays. I get hit hard this time of the year) so I scraped the buying of wheels right now and I'm looking at priorities.
Brett
Attachments
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Brett Proctor
Well-known member
Started to get the transaxle in today but of course it didn't happen. The transmission nose cone was resting right on top of the torsion tube. So tomorrow I need to find out why.
Brett
Brett
Brett Proctor
Well-known member
Got the transaxle in but still not happy with the way it fits plus the shifter that came with the car is just a universal one and that will be replaced
Worked alittle on the canopy latch system. Had to order the latch and the morris minor handle from the UK but the stuff is still out there so thats good. Didn't have a catch for the latch(another one of those things that I wonder what happened to it)so I ended up making one out of alluminum. Ran into a couple of things that are holding me up on the build but I figure if I'm doing something on it thats better than nothing.
For now I'm not going high tech(hydraulic)on the canopy lifting system like some of you.(need the money for other parts of the build)so I'm staying with stock system for now.
Haven't got any real progress to report so here are some pics of the latch
Later
Brett
Worked alittle on the canopy latch system. Had to order the latch and the morris minor handle from the UK but the stuff is still out there so thats good. Didn't have a catch for the latch(another one of those things that I wonder what happened to it)so I ended up making one out of alluminum. Ran into a couple of things that are holding me up on the build but I figure if I'm doing something on it thats better than nothing.
For now I'm not going high tech(hydraulic)on the canopy lifting system like some of you.(need the money for other parts of the build)so I'm staying with stock system for now.
Haven't got any real progress to report so here are some pics of the latch
Later
Brett
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letterman7
Honorary Admin
Cool! I wondered myself what the heck those handles came from - good to know that you were able to track that, Brett!