Fitting a 5 speed into your bug

[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.

[Bug@5speed(US)]

Thanks for the reminder.. Very true..

You'll have fun over at Martin's..

[Bug@5speed(US)]

Slide 49- Type I IRS Chassis Prep




With 30+ years of grim and dirt, now is a good time to wire-wheel and clean the bottom of the IRS mounts
Also clean the flat section of the frame horns
This will help with test fitting the gearbox and when you need to identify areas that need to be clearance

Slide 50- Type I IRS Chassis Prep



One of the first areas that you will notice that needs to be marked for clearance is the right hand side of the nosecone/intermediate plate (looking from top of chassis)

Slide 51- Type I IRS Chassis Prep



Shown here is the clearance for the reverse gear switch

Slide 52- Type I IRS Chassis Prep



Shown is the clearance for the Clutch Cable Adapter Plate and for the TOB Fork