Gearbox Re-Build

The Gearbox has been something of a trial in itself! The gearbox that came in the van looked to be the correct one, until we started investigating....... Yes, it was a split-case box, but not a full "crash" box, therefore it had a synchromesh. We assumed this was correct because the Split Beetle (when it became the Zwitter) went to a synchromesh gearbox at the same time (roughly sept / oct 1952). However, the Barndoor kept the full 'crash' gearbox till later on than the Beetle. So, bye-bye gearbox out of van!

Firstly finding a correct barndoor gearbox (yes they are different than a Split Beetle) was the biggest headache. Yes they look physically the same, but obviously by running reduction boxes, the differentials are in the opposite way around (otherwise it goes rapidly in reverse). The only visibly way to tell is that the gearbox code will start 2A-******

The first one we found was visibly perfect, until it was cracked open to reveal totally mashed-up innards.

The 2nd one was a Beetle box that visibly was a mess, but inside was like new.

So, Carl set about making one good Barndoor gearbox out of the various ones we had! Here's how we ended up:

Once the case was split, we had it chemically cleaned and then the case halves were blasted using aluminium-oxide blasting grit, then given a light dusting with glass beads. This takes it back to a factory looking fresh finish.

The very early gearboxes have the oil filler nut located to one side - its the bit with the red blob on it in the photo below:

The two red bolts are the drain bolts.

Sold axle boots complete the correct early gearbox. If you're wondering what the red 'blobs' are, its a paint finish that was added to every part that is opened / undone / drained during a service. Therefore the oil drain plugs and oil fill plugs would have left the factory with a blob of red paint of them to help the service mechanic at the dealership with its routine servicing

All we need now is the van back from the paint shop so we can fit it!!!