Fitting a 5 speed into your bug

[Bug@5speed(US)]

Slide 15 Bug@5-Speed Kit Components
Bug@5-Speed also carries Inner Shift Forks for use when converting 914 tail and side shift gearboxes


Slide 16 Bug@5-Speed Kit Components
Bug@5-Speed also carries Modified 901 and 914 TOB Forks for use when converting 901, 914 tail and side shift gearboxes
Modified forks are bent to provide better geometry
These can be purchased on an exchange basis
Lever is newly galvanized after the modification/adjustment*and equipped with a new guiding socket at the back.*




Slide 17 Bug@5-Speed Kit Components
Bug@5-Speed Gearbox Output Flanges



Come in two sized:
Stock Beetle diameter (78mm)
944/T2 diameter (86mm)
Machined and Hardened
Note: early 901 flanges have larger opening and must be specified

[Bug@5speed(US)]

Slide 19- Getting Started (Partial Disassembly)


Drain oil via two plugs on the side of the gearbox (17mm Hex Drive)
Lower plug is magnetized to capture filings
It is a good idea to inspect this plug to have an initial idea of condition of internals

Slide 20 Getting Started (Partial Disassembly)




Removing Flanges
Utilizing 1 inch square stock special tool is made to prevent flange from spinning
Bolt on flanges are size 19mm and are referred to as diff expansion bolts

Slide 21 Getting Started (Partial Disassembly)


The differential side cover/plate is secured by 13mm sized nuts
Removing of the side cover is necessary in order to flip the differential
This is necessary on the 914 gearboxes due to the 914 boxes being set up for mid engine configuration
Failing to due this will yield one fwd gear and 5 reverse gears

Slide 22 Getting Started (Partial Disassembly)


Side Cover removed exposing a poorly maintained gearbox
This is not what you want to find
With cover removed it becomes evident that in order to remove the diff, the pinion shaft and main shaft will have to be removed

Slide 23 Getting Started (Partial Disassembly)




Few more items that need to be removed to enable the intermediate plate, and gear stack to be pulled away from the case to access diff
Unbolt 2 13mm nuts to removed side cover plate; freeing inner shift rod
Removed reverse gear switch and pin

[Bug@5speed(US)]

Slide 24 Getting Started (Partial Disassembly)



With the intermediate plate and gear stack out of the way you can now pull the differential from the box
Now reinstall with differential Ring Gear facing the opposite way
Reinstall all items in reverse

Slide 25 Getting Started (Partial Disassembly)




Nosecone is secured to intermediate plate via 13mm nuts.
Once nuts are removed utilize a rubber mallet to remove nosecone
Take caution when removing the nosecone, as the reverse gear assembly may fall out/off

Slide 26 Getting Started (Partial Disassembly)



With cover removed now is a good time to transfer reverse gear shaft onto your new nosecone
Example shown of early 901 nose cone
Utilize a small punch and remove small pin
Remove reverse shaft and relocate onto Bugat5speed Nosecone
Reinsert small pin to secure/lock reverse gear shaft


Slide 27 Getting Started (Partial Disassembly)

Reverse Gear shaft shown on the old nose cone


Reverse Gear shaft and locking pin

[Bug@5speed(US)]

Slide 28 Getting Started (Partial Disassembly)


With Nose Cone removed, now is a good time to remove the speedometer drive gear
Two approaches
(1) Use a hacksaw and cut (Not best approach)
or
(2) Remove Expansion bolt (held in place with (80-87ft/lbs) and decouple drive gear (Better approach)


Slide 29 Getting Started (Partial Disassembly)



The Expansion bolt is size 32mm, and will require that you lock the gearbox down in order to utilize an impact drill to remove.
There are many methods to locking the gearbox, one such method is to utilize an old clutch disk, using some one inch stock and a few bolts (See side picture)

Slide 30 Getting Started (Partial Disassembly)



Once expansion bolt is removed from, you will notice that the speedometer drive gear is secured via a small pin
To separate remove lock pin

Slide 31 Getting Started (Partial Disassembly)



The Bug@5-Speed Nose Cone and Front Traverse are shown on the right.
With the reverse gear shaft installed and locked in, you can attach nose cone to the intermediate plate and gearbox.
Be sure to replace the factory gasket or utilize a liquid gasket to create a good tight seal
Secure to gearbox with the self-locking nuts and washer
Torque 13mm nuts to 18 ft/lbs (Per Porsche Manual

[Bug@5speed(US)]

Slide 32 Getting Started (Partial Disassembly)




The Front Traverse is secured to the nose cone via (4) hex bolts
This is what the final nose cone and traverse should look like.

Slide 33 Getting Started (Partial Disassembly)
Bowden Tube/Clutch Cable Adapter Plate Install (914)


The Adapter Plate is utilized to redirect and establish proper geometry for the clutch cable and Bowden tube
Install is accomplished by placing adapter plate onto differential side cover via two 13mm nuts
Shown is install on a 914 gearbox

Slide 34 Getting Started (Partial Disassembly)
Bowden Tube/Clutch Cable Adapter Plate Install (901)


While the 901 early gearbox has an eyelet for the clutch cable, this is not the optimal setup.
It is recommended to use the Bug@5-Speed Adapter Plate. The Plate is utilized to establish the proper geometry for the clutch cable and Bowden tube
Install is accomplished by placing adapter plate onto differential side cover via two 13mm nuts
Removal of the 901 eyelet will be necessary.
This can be accomplished by cutting the old eyelet and plugging hole with automotive plug
Failure to plug hole will yield hole in side cover

Slide 35 Getting Started (Partial Disassembly)


In order to attach the cable extender to the 901 or 914 Tob Fork, you need to attach the adapter piece which will serve as a guide for the knurled extension

[Bug@5speed(US)]

Slide 36 Bug@5-Speed Rear Gearbox Support



This is the bell housing side of the gearbox.
The rear gearbox support is attached to the bell housing via beetle transmission mounts.
It is affixed to the two flat areas on the bell housing


Slide 37 Bug@5-Speed Rear Gearbox Support (Cont)



Both variety of transmission mounts can be used with the Bug@5-Speed Traverse
To begin the installation process, you must mark where the attachment holes will need to be


Slide 38 Bug@5-Speed Rear Gearbox Support (Cont)


With the bell housing marked, use a punch and hammer, to mark the pilot holes for the drill bit

Slide 39 Bug@5-Speed Rear Gearbox Support (Cont)



With the 4-holes drilled into the bell housing, the next order of business is to utilize a grinder or dremmel with grinding bit to create a flush mounting surface for the transmission mounts

Slide 40 Bug@5-Speed Rear Gearbox Support (Cont)


The last order of business is to attach everything to the bell housing with the manufactured supplied bolts/nuts or grade-8 or better hardware

[Bug@5speed(US)]

Slide 41 Bug@5-Speed Output Flange Install



When ordering its important to know if you have the early 901 sized flanges (Large) or 914 flanges (Small) due to the different sized hole in the flange.
Bug@5-Speed Flanges are affixed to the differential with the removed washer and expansion bolt (It is recommended that you replace bolts with new ones
Tighten to recommended manufacture specification