Bore scope for gearbox inspection, O1E

[Tim]

Purchased a O1e box with a thirty day return policy,I don't want to strip it down.
Can any of the fittings be removed for a bore scope inspection?, or is it not to tricky to pull down?.
I've rebuilt engines & gearboxs in the past, so I'm ok with this kind of work.
Is the any downloads for the Audi box?, not seen any on the google etc searches.
Thanks

 

[Stephane Goria]

Hello,

I do not deal with Audi gearboxes, just UN gearboxes, but for sure if I had sold a rebuild gearbox with a 30 days money back guarantee and the buyer returns me the gearbox that has been opened, clearly I won't refund...

So I would recommend you to take care of this.

Also a "bore scope inspection" will not give you a way to inspect a gearbox from outside. How do you intend to be able to see, for example, rusted bearing tracks, worn dog teeth or tired synchomesh rings just looking at the assembly. These are inside parts that can be checked only by dismantling the assemblies and having the single part in hands to have a close inspection...

Why don't you test it from outside ?

Unless chipped teeth or any other mechanical troubles, you won't see anything and so to check this you can do the method described below :

Do a little assembly to connect a 1.5 - 2hp electric engine to the input shaft, and have then the input shafts to rotate around 500 rpms, this allows to shit gears then once the gear engaged you can increase the rpms. This process allows to have a first good diagnose of no major troubles in the gearbox, hearing noises and controlling how gears engage

If any troubles here, you MUST send back the gearbox and as it won't have been opened , you should have your money back

Greetings

Stephane

 

[Tim]

I note your comments thanks, I'm not to worried about bearings as long as the gears are good,(they can go hand in hand i know).
I have checked for debris in the oil & it is very clean, the drain plug has not been removed for some time.

 

[Scott]

I'm afraid there is no hole you can inspect the gears with. You can however inspect gear clusters 1-4 by splitting the gearbox the differential housing and center section and inspect gears 5-6 by removing the end case. However yopu will need new sealant and sealing cap to put it back together.

Even if the oil is clean there still can be debris in the box, after the box sits for awhile the particles will collect on the bottom of the case, and very little will be drained with the oil. Also the magnets will collect most metallic debris.

First gears, and pinion bearings are big problems with these gearboxes, a large percentage of them had the pinion preload set too tight from the factory which will cause the pinion bearing to pit and make a loud noise we have to replace the pinion bearing in about 40 percent of the gearboxes we rebuild.

First gear also can take a beating for poorly driven gearboxes. If the first gear is damaged the cost to repair is large as you need new first gear and mainshaft.

 

[Tim]

Thanks Scott good info, pinion bearing preload,are some of the bearings taper? is this as in shims to thick & loading the bearings?.

 

[Scott]

Thanks Scott good info, pinion bearing preload,are some of the bearings taper? is this as in shims to thick & loading the bearings?.

You are correct, the pinion bearing and rear output bearing are tapered and adjusted by shims.

The pinion depth is adjusted by shims behind the pinions bearing cone (race) the preload is adjusted by shims behind the rear output shaft bearing.

The Audi/VW 01E's exhibit the same pinion bearing issues as the Porsche 968 gearbox as they were manufactured at the same plant.