RE: [T3] Berg 5

["Erkson, Toby" <toby.erkson@intel.com> (by way of Greg Merritt)]

Good question, how long did it take?

I ordered the kit and also talked with Harold Carter (very familiar with the
kit) for a new performance tranny.  3-4 months later the main shaft was
worked by GB and the tranny assembled.  After receiving the tranny I drove
my baby to my mechanics home shop.  We swapped the trannies then proceeded
to test fit the drivetrain in and out, in and out, in and out, clearancing
the torsion housing so the nose cone wouldn't hit it, then positioning the
new frame horns and measuring/welding them in.  (Read the MS Word document
that's downloadable from my site for more detailed information.)  I want to
say it took two full weekends to get it done so we were satisfied.

Breaking-in the tranny was difficult because of this special tranny and we
weren't sure if the synchros were just being difficult (they were, very much
so!) or if something was not in alignment, either in the new shifter or the
positioning of the tranny.  Fifth gear was a real bitch to break-in because
the car had to be moving.  But things finally did smooth out :)  It was a
couple of hours to break-in the tranny enough for me to feel comfortable
driving her home and making sure everything was perfectly adjusted,
including checks to the mounting system.

I guess it took about 6 months or so, just taking my time.  The biggest time
sinks are 1) waiting for GB to rework the main shaft as they only do them as
a batch every few months, and; 2) fitting the tranny to the body.

Grinding and welding tools are a must and an experienced welder essential!

Hope this helps.  I'll see about putting a compressed version of the
document on my web site so it doesn't take so long to download (should be
available by tomorrow).

   Toby Erkson
   air_cooled_nut@pobox.com  <-- Please use this address for email
   '72 VW Squareback 1.6L bored and stroked to 2.0L, Berg five-speed
   '95 VW Jetta III GL 2.0L, P-Chipped, Jamex sport suspension
   Portland, Oregon, http://www.icbm.org/

>-----Original Message-----
>I looked at your page and am curious about how much time it took to install
>the Berg 5...


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