091 mealpart and metal shavings

[ytsejam82]

I was just changing the bellhousing on my (new to me and untested) 091 gearbox and tapped the oil to find this and metal shavings, anyone recognize where it can be from?

I have a 002 gearbox, how much parts do they share? i think if i can change the part thats failing, all the gears seems to work, without any bad sounds. a little trouble with , i think it is 3/4 but it work.

[SGKent]

where did you find the piece? Is it magnetic?

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“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[ytsejam82]

It is magnetic steel, i i found it on the drainplug

[timvw7476]

my guess: cracked portion of a gear selector fork.

[SGKent]

I thought the same then compared it to 091 forks and could not match it.

https://weddleindustries.com/products/1000168?=Apply&field_transaxle_type_tid=1000357

It looks cast and the diff carrier and cover are cast but I could not match that either.

Between Weddle and this thread there are lots of 091 photos here. Maybe something will match. http://www.thesamba.com/vw/forum/viewtopic.php?t=630932&highlight=091+rebuild
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Wildthings]

Since it didn't blow the tranny apart, I would guess that it might be part of the reverse gear.

[SGKent]

After blowing the image up I am thinking it is a what is left of a tooth. Maybe reverse idler or reverse. But I cannot be sure and wouldn't put money on it.

https://weddleindustries.com/products/1000155?=Apply&field_transaxle_type_tid=1000357

_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Wildthings]

If the piece had come from the main part of the gear box it would likely have gone through the gears and torn the crap out of everything. Since the drain plug doesn't really look that bad I am thinking a failure in the reverse gear setup. I have busted them before without damaging the rest of the gear box.

[ytsejam82]

I have now looked and i cant find any missing part of any of the three gears i can see at behind the bellhousing

hard to see at picture, but the end thats facing down on table is flat under.
and its not the same on both the long sides, the one we see are wedge shaped and shows wear like it would be a tooth, and the one on the other side i flat.

[Wildthings]

Possible a part of one of the slider/hub assemblies?

[Tcash]

Maybe part of a slider hub?
Tcash

[timvw7476]

that "band" right through the topside of the tooth would seem to make it
a reverse idler gear tooth.
At least it's easily accessible & cheap.

[SGKent]

tilt the bell housing up on a 4x4 cause it still has lots of gear oil in it, pull the bell housing and take a look at the reverse idler gear as well as the ring and pinion for damage.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[ytsejam82]

Found this in the thread, the third gear part, maybe the opening tooth?

Looks very suspicious.
Is it very hard to change it? need special tools?
I have a 5rib 002 and can get a 091 mid shift trom a t3. do they share the part?


Or may it be possible to use the gearbox as is is? (i know very hard question to give an answer to)

[Wildthings]

[SGKent]

You would need about $2000 USD in special tools and at least another $1500 USD in parts to rebuild it properly. When I rebuilt mine http://www.thesamba.com/vw/forum/viewtopic.php?t=630932&highlight=091+rebuild I had rebuilt many other gearboxes before, and three or four people who rebuild the 091 for a living coached me for which I am very thankful. I think you should look for another gearbox.
_________________
“Most people don’t know what they’re doing, and a lot of them are really good at it.” - George Carlin

[Tcash]

[ytsejam82]

Ok another box it is then :/
Is it possible to change the diff "easy" is there different gear ratio on the diff or whats it called?

Thanks for advice!

[sodbuster]

Glad you all sussed it out. that is a common failure with the 091 transaxle. It's seen mostly on the 3rd and 4th gear selector hub, and the break occurs at one or more of the three slots for the selector "dogs". the pics below show the exact areas these parts break. good lucj with the repair.

[Wildthings]

If you have a 2.0L or a really good running 1.8L engine then the stock gearing in a 091 works very well. If you have a 1.7L then the 091 gearing may be too long to give you acceptable performance.