[Chris S]

I will email them to you over the weekend.

[Chris S]

And now here

[Chris S]

No, its in for life, and to be honest I don’t think you can even buy the fluid.

[Chris S]

As long as your rear diff & transfer box are working normally & not damaged then there is no problem to running minus the propshaft in 2wd.

[Chris S]

And bought last week end by dannyp, is it in pieces yet Danny?

[Chris S]

Well here is what it looks like the VW section is outlined

[Chris S]

Lets move all future transfer box related posts from this thread over to here please
http://www.vwsyncro.co.uk/data/forums/topic.asp?TOPIC_ID=1969

[Chris S]

The smaller bore return is for a carburettor engine which works on about 3.5 to 5 psi (mechanical) pump pressure, the larger bore return is for the injection cars which work at somewhere around 50 psi (electrical) pump pressure, an obstruction in the return pipe at 5 psi is not to much to worry about, at 50psi its an entirely different story hence the greater diameter return pipe on the injection cars.
Well its either that or maybe VW had run out of the thicker pipe the day they made your Syncro!

[Chris S]

Yes it was from another Syncro, the 2wd pipes are too short to reach the tank connections

[Chris S]

You have a late type Rallye gearbox with oilways which means you can fit a 35i G60 Passat transfer box,
and as VW no longer stock any of the internals for the ASU transfer box this is realistically your only option other than changing the complete box for a Passat type one.

Even if VW did still have the parts needed to repair your transfer box they would cost over 600 pounds which with labour & vat added on would not give much change from 1000 pounds in total.

I wouldnt drive to far with your box in this condition as you are very likely to have shed some of the gear teeth from the bevel drive in the transfer box,
and as these teeth or more likely pieces of teeth are made of hardened steel it wont take them long to totally destroy you gearbox completely & utterly.

What you are looking at is either a complete teardown & reconditioning of your existing gearbox mainly to remove all loose metal particles and then rebuilding using a 2nd hand Passat type transfer box, while this is a more expensive option but at least you know that all the internals are good.
or getting a 2nd hand box and fitting it.

[Chris S]

Your gearbox code is here,

http://www2.plus8.net/jpegstore/uk/vwsyncro_chriss/p_preview.asp?fileName=d833%5F1%2Ejpg&archive=Technical+info

The semi circle at the top left is where the starter motor sits & the bolthead at the bottom of the picture is the gearchange tower, you are looking at the gearbox from over the left wing, your code will probably start with ASU.

[Chris S]

Quote, I am having a bit of bother at the moment with my transfer box.

Ouch, any idea what your gearbox code is?

[Chris S]

Sorry but that wont fit, it has been tried before many times and it hasn’t worked

[Chris S]

Might it be possible to fit a Golf 2 rubber mounted non G60 type screen

[Chris S]

This certainly is the place for questions, Answers a a different matter though. []

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