Top Aircooled VW Transmission Upgrades

Whether you crave performance or wish to improve the overall driveability of your aircooled VW there are a number of upgrades you can do with your transmission to make things better behind the wheel. 

Allow us to guide you through a few choices available when it comes to clutch and gearbox parts. 

There is no point working with things that are broken, so start with these really simple tasks that can be done to make driving your classic VW more pleasurable. 

• Check the condition of your clutch cable and ensure it operates freely within the clutch cable conduit. If this is in poor health, then it will need replacing.
• Check the condition of your gear shift bushings and couplings to ensure the connecting shaft is sitting straight and selecting the gear cleanly with each shift.
• Top up or change your gearbox oil, depending on when it was last done. 
• Check and renew the gearbox mounts if required. Worn gearbox mounts can cause engine judder and wheel hop (intermittent loss of traction) on hard starts. This is probably the number one cause of transmission failure. 
• Inspect and renew axle boot and CV joints and boots if required. 

With a limited budget and a bit of time you can add some longevity and additional performance to your aircooled VW transmission without being a master mechanic. The following ideas may appeal. 

• Fitting a longer clutch arm to reduce the heaviness of the clutch pedal. 
• Fit a front gearbox support bar to reduce gearbox movement, or use an intermediate mount for Splitscreen models. An engine traction bar fitted under the rear of the engine is a must if you are racing or driving hard on the street. 
• Fit heavy duty/urethane gearbox mounts. 
• Fit a short shift plate under the stock gear shifter to reduce the distance you have to push the lever to select each gear. 

This list may cost you some more time in the garage and a few hours of overtime too, but you'll be glad you made the effort. 

• Fit a performance gear shifter. Not only do they reduce the throw, but they are ergonomically designed to be more comfortable, and with a choice of designs you should find something to suit your style. 
• Fit an uprated clutch shaft kit. 
• Upgrade your early car or bus to the more reliable later clutch release bearing Don't forget to order the adapter sleeve though. 
• Fitting a Freeway Flyer gearbox. This will reduce engine revs in 4th gear, improving economy, engine wear, top speed, and driver comfort. 
• Fitting an upgraded clutch disc and stage 1 pressure plate. Your standard 200mm Type 1 clutch will cope up to 90bhp, but after that, it is time to make a change to ensure you're not losing power. 

If taking a gearbox apart and custom fabrication is your idea of fun then this list is for you, especially if you are drag racing or running a high-performance motor. 

• Fit Super Diff if you are running an IRS gearbox in a race car or off-roader. These are much stronger and built to cope with high RPM launches off the line.  
• Rancho Gearbox rebuild with custom ratios for faster acceleration or higher top speed. Get in touch with our team to find out what would suit you best. 
• Convert to IRS gearbox and rear suspension. This is particularly popular with Split bus owners looking to remove the reduction boxes and lower the van whilst keeping the rear wheels sitting upright. Likewise, Beetle and Ghia owners taking part in track activity much prefer the handling characteristics of I.R.S. and often convert an earlier car to use this system. 
• Porsche 5-speed gearbox conversion. The 901 code gearbox from a 914 /912 is the easiest transplant option, but the 915 gearbox will take more power (although is a more complicated install). Sadly neither will be cheap or in stock at your local scrap yard as they are also in demand by Porsche owners too. 

We hope this guide has given you a few ideas for some forthcoming projects on your aircooled VW. Perhaps even a couple of parts to ask Santa for? 

Andy