Fitting a 5 speed into your bug

[Bug@5speed(US)]

Slide 28 Getting Started (Partial Disassembly)


With Nose Cone removed, now is a good time to remove the speedometer drive gear
Two approaches
(1) Use a hacksaw and cut (Not best approach)
or
(2) Remove Expansion bolt (held in place with (80-87ft/lbs) and decouple drive gear (Better approach)


Slide 29 Getting Started (Partial Disassembly)



The Expansion bolt is size 32mm, and will require that you lock the gearbox down in order to utilize an impact drill to remove.
There are many methods to locking the gearbox, one such method is to utilize an old clutch disk, using some one inch stock and a few bolts (See side picture)

Slide 30 Getting Started (Partial Disassembly)



Once expansion bolt is removed from, you will notice that the speedometer drive gear is secured via a small pin
To separate remove lock pin

Slide 31 Getting Started (Partial Disassembly)



The Bug@5-Speed Nose Cone and Front Traverse are shown on the right.
With the reverse gear shaft installed and locked in, you can attach nose cone to the intermediate plate and gearbox.
Be sure to replace the factory gasket or utilize a liquid gasket to create a good tight seal
Secure to gearbox with the self-locking nuts and washer
Torque 13mm nuts to 18 ft/lbs (Per Porsche Manual

[Bug@5speed(US)]

Slide 32 Getting Started (Partial Disassembly)




The Front Traverse is secured to the nose cone via (4) hex bolts
This is what the final nose cone and traverse should look like.

Slide 33 Getting Started (Partial Disassembly)
Bowden Tube/Clutch Cable Adapter Plate Install (914)


The Adapter Plate is utilized to redirect and establish proper geometry for the clutch cable and Bowden tube
Install is accomplished by placing adapter plate onto differential side cover via two 13mm nuts
Shown is install on a 914 gearbox

Slide 34 Getting Started (Partial Disassembly)
Bowden Tube/Clutch Cable Adapter Plate Install (901)


While the 901 early gearbox has an eyelet for the clutch cable, this is not the optimal setup.
It is recommended to use the Bug@5-Speed Adapter Plate. The Plate is utilized to establish the proper geometry for the clutch cable and Bowden tube
Install is accomplished by placing adapter plate onto differential side cover via two 13mm nuts
Removal of the 901 eyelet will be necessary.
This can be accomplished by cutting the old eyelet and plugging hole with automotive plug
Failure to plug hole will yield hole in side cover

Slide 35 Getting Started (Partial Disassembly)


In order to attach the cable extender to the 901 or 914 Tob Fork, you need to attach the adapter piece which will serve as a guide for the knurled extension

[Bug@5speed(US)]

Slide 36 Bug@5-Speed Rear Gearbox Support



This is the bell housing side of the gearbox.
The rear gearbox support is attached to the bell housing via beetle transmission mounts.
It is affixed to the two flat areas on the bell housing


Slide 37 Bug@5-Speed Rear Gearbox Support (Cont)



Both variety of transmission mounts can be used with the Bug@5-Speed Traverse
To begin the installation process, you must mark where the attachment holes will need to be


Slide 38 Bug@5-Speed Rear Gearbox Support (Cont)


With the bell housing marked, use a punch and hammer, to mark the pilot holes for the drill bit

Slide 39 Bug@5-Speed Rear Gearbox Support (Cont)



With the 4-holes drilled into the bell housing, the next order of business is to utilize a grinder or dremmel with grinding bit to create a flush mounting surface for the transmission mounts

Slide 40 Bug@5-Speed Rear Gearbox Support (Cont)


The last order of business is to attach everything to the bell housing with the manufactured supplied bolts/nuts or grade-8 or better hardware

[Bug@5speed(US)]

Slide 41 Bug@5-Speed Output Flange Install



When ordering its important to know if you have the early 901 sized flanges (Large) or 914 flanges (Small) due to the different sized hole in the flange.
Bug@5-Speed Flanges are affixed to the differential with the removed washer and expansion bolt (It is recommended that you replace bolts with new ones
Tighten to recommended manufacture specification

[Bug@5speed(US)]

Slide 42- Relocating Oil Breather





When using a 914 box it is necessary to relocate the oil breather tube to the same location as it would be found on a 901 box
Bottom picture shows where the new location will be on the 914 box

Slide 43- Relocating Oil Breather (Cont)


Some of the tools you will need to accomplish this task:
Oil Breather
Thread Pitch gauge
Small drill bit for pilot hole
Large bit
Punch
Tap and Handle

Note: Remember your safety equipment (eye protection)

Slide 44- Relocating Oil Breather (Cont)




Use a Punch to mark the new location of oil breather tube
Ensure new location of tube clears case internals

Slide 45- Relocating Oil Breather (Cont)


Use a small drill to create pilot hole
Use appropriate large drill to open up hole to correct size for tapping
Use gauge to verify correct tap size
Using cutting oil, and tap with handle cut new threads onto case

Slide 46- Relocating Oil Breather (Cont)




Lastly fit breather into new location. Breather should have approximately 45 degrees offset
Plug old hole with automotive plug
Oil Plug can be used

[Bug@5speed(US)]

Slide 46 Type I IRS Chassis Prep


Installing the Bug@5-Speed Conversion kit can be done with body on or off.
When installing the kit, it will be necessary to remove the old beetle transmission mounts as shown in the top picture
A grinder and some eye protection make quick work of the transmission mount bolts
This is what chassis should look like after bolts are ground off and surface made flush

That's it for today..

Tomorrow the rest of chassis prep
Enjoy and comments always welcome.
Alex

[Turbo Haraune2]

Lots of good info here... but let me add a $$$$ tip: Use Loctite on all bolts and nuts on initial thighting! or they wil vibrate loose.
Cant wait to pick up my parts and start the conversion!
Going to visit Martin in January.