<x-flowed>>
According to my measurements, it still is 2mm longer than Russ'smeasurements. This did not stop the cover fitting however. From the way that itfelt as I worked on it last week, I believe that it originally would have stopped the cover closing fully, even with the correct o-ring.The extra length is probably not a problem, and it just means that the square hole in the drive gear is deeper than the peg that fits into it. It's probably broached all the way thru, but that would mean that you didn't need to shortenit at all.
Without knowing exactly what the gear looks like that the governor slots into, I can't be sure what was going on. However, the head of the governor certainly did sink deeper into the diff as I shortened it, giving me the impression that it could hit bottom. The tip of the governor slotted deeply into the gear, I had to pull it out quite some way until I could rotate it. As I inserted it, it felt like it met some resistance, which I assume was the gear, and then as I twisted and pushed it, it went a good few millimeters further in, as it engaged in the gear.
BTW, did you compare the width of your square peg with the measurement Russsent you? I believe that was 4.41 mm.
No. The one that was in there before was 5mm wide. My caliper is not digital, so it doesn't give such precise measurements
It seems OK, although I only drove it for a few minutes. It did seem to slipslightly at half throttle between 2 and 3. Apparently I need a semi-self-destructed governor for really good shifting ;~)Some slippage might be expected if you are still a bit low on ATF.
I'll check the ATF level again tomorrow. It probably is still a bit low.I didn't mention before that the gearchange is extremely smooth - almost unnoticeable. I wish some of the modern cars that I have driven had such smooth gearchanges. Before, as the governor fell apart, the gearchanges got wider apart, and they changed with a bit of a bump.
D.
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ </x-flowed>