[Vwdiesel] Rabbit halfshaft questions

[LBaird119 at aol.com]

 Are the halfshafts the same in the '82 Rabbit (5-speed) and the '84 
Rabbit (4-speed)?

  The only difference might be the diameter of the inner joint.  Otherwise 
they should be the same.

> 
>   What are 'rebuilt' halfshafts?  What parts are replaced?  Is any
> machining involved in the rebuild?

 New paint, boots, clamps, grease.  I've heard various things 
as to just how rebuilt they are.  Most common "rumor" seems 
to be they use larger balls then machine the slots out for the 
larger size.  Same rumor says no surface hardening after the 
machining/grinding.


> 
>   Should I just replace seals &boots and regrease everything and run 
> with the old halfshafts?


  If they don't clunk or even clunk mildly, I tend to do just that.  I even 
tend 
to pay about the same for one new outer joint rather than go with a rebuilt 
shaft.  Many like and use the warranty replacement of rebuilt shafts.  I 
prefer the known dependability of a new joint on my otherwise good parts.

> 
>   Should I replace the final drive seals?  No leaks yet, but maybe I 
> should do it while the transmission is on the bench...


  Usually doesn't hurt but if you REALLY want to do it right you might 
consider new flanges while you're at it.  Give them a wiggle and see 
how much wobble they have on the output shafts.  If they're tight I'd 
almost be inclined to leave well enough alone.  You don't often see 
flange seals that don't at least weep a little.

> 
>   What should I pay for a pair of rebuilt halfshafts?
> 
>   Where is a good place to buy rebuilt halfshafts?  I live in SW WA.


  Not sure as my supplier's prices tend to favor new joints over shafts 
slightly.  Most of the local places have much better prices on rebuilt 
shafts than joints.

> 
>   Does anyone know of any particular gotchas in this engine/trans swap?


  Just don't forget the little plate behind the one CV joint that closes off 
part of the clutch area.  Hard to get the tranny out with that one still 
on!  Some want the flywheel in a particular place, where there's a 
recess to help clear the CV joint.

> 
>   What sort of new &different stuff will I need to get the '82 5-speed 
> to fit in the '84 Rabbit (originally a 4-speed)?  New shift linkage parts?
> 

  You need the 5 speed motor mount.  It has 2 horizontal bolts where the 
4 speed has 4 vertical bolts.  You also need to change one or both of the 
clip-release-snap-on-plastic-joint shift linkages.  I was told you have to 
change the whole shift linkage assembly.  I simply change the one or two 
linkages and did a little fine adjusting and have all gears on the original 
shifter.  :-)
     Loren