Project Slowly Underway: Berrien 295

[MadMike]

all u need is a Press and a Jig and know what to look for,,,,,,,,,,,,,,,,,,

[vanapplebomb]

Actually, I don't think you need a jig to set up the shift forks in an 091-1 like you do with the bug, 002, or 091 transmissions. From what I understand, they are fixed in place. But like I said, transmissions are not my thing, so I'll let him tackle that, unless you want to have a crack at it.

[MadMike]

Thanks for the offer Dirk,but I'll pass,I'm busy enough for now

[vanapplebomb]

No problem Mike.

[vanapplebomb]

Went to check out the 091-1 from the 1990 Vanagon yesterday. Looks like it will be a good starting point.

I talked to a guy at church today who owns a glass shop. He can pick up my frame, cut, and install a safety glass windshield for me.

[MadMike]

Good Idea on the windshield street legal someday?
=more driving time

[vanapplebomb]

Jun 23, 2016 7:02:02 GMT -5 MadMike said:

Good Idea on the windshield street legal someday?
=more driving time

Yeah, I'm putting it in anticipating that I may want to title it some day. Figured popping in a windshield now is as good of time as any.

[vanapplebomb]

So I cracked open the bell housing on the "new" 091-1 transaxle and what do I find???

Factory four spider gear differential. Oh yeah, looks like the R&P is in fair shape too!

[MadMike]

Please don't make this a "4 year trans build"
Great score

[vanapplebomb]

Shouldn't take too long. The intermediate housing will need to be rebuilt to restore the press fit on the main shaft ball bearing behind the constant mesh reverse gear in the picture below. Most likely will get sent in as a core and replaced with one that has been machined for a steel pressed in sleeve. A real reverse gear and beefy diff will be an asset for trail riding up north!

[MadMike]

Benco in Riverside is sending a call tag for my spare 3 rib

[vanapplebomb]

Not familiar with a call tag Mike, q me in.

I got the bell housing cradle clearanced. Took a bit of grinding to get it to clear the reinforcing ribs on the underside of the bell housing. Looking into making a front mount similar to what the Vanagon had. Plan right now is to have a urethane trailing arm bushing in a piece of tubing welded to a plate. The plate will be bolted to the top of the rear torsion housing with a pair U-bolts. The front the the transmission will get a plate with a couple tabs on it to capture the sides of the trailing arm bushing. At least that's the plan.

[MadMike]

He's supposed to buy my 3 rib, sending a crate & tag (call tag is prepaid postage

[vanapplebomb]

Ohhh, that's what you were talking about. My bad. Thanks.

[vanapplebomb]

Ibfound a coating place in west Michigan that has a 2000degF black ceramic coating for headers. Gona drop off the exhaust parts there soon to get ceramic coated.