This is the Resurrection a VW T3 syncro gearbox rebuild. In keeping with the easter spirit (this box was finished at Easter but been so busy Ive only got round to finishing this post today ) I thought it would be good to conclude this story at this time of year. For those of you who have read the first and second installments cataloguing the destruction of the internals of this gearbox. I have manged to provide the owner with very good replacements. These which combined with new bearings, seals and combined with SA oiling plates a HD 3/4 th gear synchro hub and the installation of an AJT mainshaft bearing retainer plate should ensure it gives trouble free motoring.

Replacement Internals VW T3 Syncro Gearbox
Build Notes VW T3 Syncro Gearbox
Gears
Crown and Pinion
Very good crown and Pinion installed Locking Differential installed
5.43 Final Drive
Crown wheel bolts all torqued up to 50nm
Good 1st gear
Late good used 1/2nd Synchro hub round slots crack tested with good springs and keys and new ½ slider
New circlips VW no 091 311 321A
Very Good used 3rd gear z=40
Very Good used 4th z =50
Very Good used Pinion Lock ring / 1st gear inner race and refurbed needle bearings
Very Good used 2nd gear
Very Good used fixed 3rd gear oil face towards 2nd gear
3rd gear circlip 2.3mm
Good used 4th gear
Half mon circlip installed
Good used Mainshaft installed z= 9/16 teeth
Good used 3rd gear
Good used 4th gear
Heavy duty Weddle 3/4th Syncro hub installed with excellent used ¾ slider springs and Keys
New Syncro rings provided
All case holes tapped and cleaned, and mating faces cleaned
Bearings
New Pinion Bearing installed FAG Z53106801TR2 made in Hungary by FAG
New Differential bearings installed, preloaded and run in at 47nm
1st, 2st R gear, Rev idler and G idler cages refurbed, and needle bearings replaced with new
New 3rd and 4th needle bearings 2 x VW no 02a311265D lot no RA 148 3077 4837
New Mainshaft bearing installed Z-36138802KL-AM made in Slovakia 0045 10Ă—0717 by FAG
AJT Mainshaft bearing stop plate installed Reduction housing skimmed
New Mainshaft rear bearing installed 094 311373
New pinion bearing installed 094311373c
Front Mainshaft bearing installed 094311375
All new shift fork bearings 091301120 installed
New Ggear bearings 094311370 installed x 2
SKF 6026 111213P made in Italy
New SKF 6308NR 0812 0855P made in Italy
Other Notes
Selector shaft bush renewed and seal
Relay lever housing re-sleeved and relay lever checked for play in rivet
4th gear oiling plate installed all shift rods installed
New lock ring installed and Synched
Backlash = 18+/- 2
Selector shaft installed with cup and spring and new plastic bush and seal with external spring installed 020141733D
New selector shaft boot, new ball and boot for ball, washer and stainles steel nylock nut
New rev housing installed with new paper gasket and o ring seal
Output flange seals installed and O rings Adjusting rings set up on marks
Oiling plate installed
Input shaft installed with spud and Muff and new circlip
Good used Reverse gear
Green spacer oil gap =0.45
Good used R/G syncro Hub
Other circlip installed
Good used R/G Synchroniser no play in rivets Moly ok
Good used Ggear
1.2mm thrust spacer used
New SKF 6308NR 0812 0855P made in Italy installed on good used reduction gear
Reverse idler installed with refurbed needle bearings spacer ring and thrust bearings and shortened shaft
G gear idler installed with refurbed needle bearings spacer ring and thrust bearings and circlip fitted
Good used Nose cone
Muff installed and a new 6026 SKF bearing 111213P made in Italy and new Corteco seal installed on Output shaft
Bell housing cleaned clutch fork removed clutch fork bush cleaned and reseated and relubed HD Weddle bronze clutch sleeve installed new input flange seal
4mm RJES clutch bracket spacer and new clutch bracket installed (old clutch bracket was fractured RJES spacer prevents this )
Case Painted with 2k etch primer and 2k custom gold colour detailed with 2k
Clutch fork put on and new circlip installed
Output flange domed washer, new circlips and bungs installed both sides
All case bolts torqued
Output Flange front nut torqued
Seal for Diff lock sleeve installed
New actuator
New Stainless steel actuator Bracket, and new roll pins provided
All gears select properly
Crated and lined with black foam ready for shipping.

Good used VW T3 Syncro Mainshaft 094311101B with 3rd and 4th gears, new syncro rings and 3/4 Synchroniser

Mainshaft bearing retainer plate installed

Skimmed reduction gear housing

Pre-paint


Ready for crating and shipping

Looking so nice finish box.
My 1989 gas syncro 4-speed lost 3. and 4. gear and im lost now. Nobody seems to understand how it will be live agen. Im from Finland.
How much rebiuld cost about? Shipping x2 times also