So a bit of an update. Nothing really changed over the last few years, Corvair engine running well just could do with a longer 4th gear, which let’s face it is the main issue if your running a big engine. So the opportunity arose to purchase a recently rebuilt 002 gearbox with a longer 4th. I also had an oil pan leak that I was unsuccessful in fixing last summer and a noise that I suspected was the gearbox that again was unsuccessfully investigated last summer when the engine came out on my drive to replace the clutch bearing.
So with the 002 gearbox in the garage, the new oil pan seal waiting and a few jobs on the engine planned namely new lighter duty breather connections and a permanent solution to blocking off the hot air ducts on the engine other than the gaffer/aluminium tape and with some extra time on my hands I got started.
I’ll add the pictures for reference and add some comments later
Engine out
091 box out
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Gear rod out and bushes were replaced
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091 with 002, seals were replaced on final drive on the 002 just in case, note new oil seals a lot thicker than the old ones that were only replaced 2/3 years ago and weeped
Bell housing swapped
Whether or not the 002 will prove to be strong enough remains to be seen. A bit of paint
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I was looking at a solution to get heat into the bus, I figured I could weld a plate with a spigot over then I noticed there was 3 threaded holes, so had a rethink and made some alloy plates and loc-tited them in place. As I need to work out a valve system for the heating I have shelved the heating system for now but should be easy to do in the future with these removable plates
I also had an issue where the alternator packed up on a really hot run back from Camper Jam, I had it repaired locally but since has always pumped out 16volts, when returned to the repairer his machine indicated 14.4v, I figured his equipment was at fault so went for a second opinion, yet you guessed it, they had the same 14.4v results. So I’m still at a loss with this one, my fluke meter and VDO gauge both indicate 16v whilst running??
002 box in, was a bit worried with this as an 091 box needs to be modified to fit an Earlybay and I recall the guy who fitted it had to modify the nose mount to make up an inch deficit, luckily he drilled the mount and moved everything back at the time when mounted to my 1776 engine, so with the 002 mounted as VW intended everything lined up and all gears present and in good order
Drive shafts on
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Engine in less alternator
Alternator back and engine connected with freshly painted valance
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At this point I went to CJ Motors and used Nicks 2post ramp to change the oil pan seal, the last time I attempted it was on my drive, it was hot and cramped under there and once was reassembled it leaked more than it did before! Pissed off to say the least!! This time I prepared, cleaned and the most important this was knocked the oil pan back into shape where it had been over tightened it had deformed.
No pictures of this but happy to say I’m leak free
Back home and final assembly of Westy towbar and bumper, the most fiddly part of the who job!
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And back in the game
So the noise I was experiencing which I thought was gearbox related is still there, it was when changing direction mainly when reversing out the garage, only happens with clutch depressed so I can’t get out to investigate! Nick had a listen at the garage and says it sounds like a vibrating tin type of noise, good news is it’s nothing to worry about and I know my 6Rib box is a good spare. The 002 box has a noticeably longer 4th which is well suited to the engine and will make cruising easier on the ears!
Gear shift is smoother with the new shift rod bushes and the vibration I had through the gearstick seems to be greatly reduced, I’m not sure it’s completely gone but a motorway ride out will confirm for sure.
Hope everyone is well during these tough times
