Transmission replacement

[Iheartboost]

I am wanting to replace my awd 5 speed in a 90 TSI, but don't know how many splines are o the output shaft. What's a good cheap source? I've found the best price at jacks transmissions so far; $499.

 

[LiquidX]

Jack's Transmissions is freaking amazing. I will always recommend people to go though him from now on after my recent email with him about my tranny. His customer service is honestly one of the best I have seen in any company to date so far from said email

 

[Iheartboost]

Jack's Transmissions is freaking amazing. I will always recommend people to go though him from now on after my recent email with him about my tranny. His customer service is honestly one of the best I have seen in any company to date so far from said email

That's great to hear, i've looked at his entire site, and it really seems like they know what they're doing with dsm's (especially with the double-synchro 2nd mod, and evo conversions.) Anyone else have tips? I hear these trannys are known to grind to bits, I don't want to replace it twice because of junk.

 

[Iheartboost]

so how many splines is my tranny? how can I tell without pulling it?

 

[thomcasey]

so how many splines is my tranny? how can I tell without pulling it?

Are talking about the output shaft to the clutch or to the transfer case? If it is the transfer case, they are normally 22 up to 92 where it changed to 23. As for the clutch, I do not believe it matters as they are they did not change that.

You can verify the transfer-case spline count by dropping the transfer case and counting the splines on the output shaft. If everything is original, you will have a 22-spline.

 

[90gst_sean]

cheepest is not always the best (Jacks)!

 

[XiKeiyaZI]

Yeah, if it's a 90 Transmission then it's a 22 Spline transmission.

You can also either buy a new one, get yours rebuilt by a reputable service, or find someone from here with a spare one.

Also, you can go ahead and install a 23 spline transmission, but there are a few things that have to be done for it to work completely perfect.

 

[Iheartboost]

Yeah, if it's a 90 Transmission then it's a 22 Spline transmission.

You can also either buy a new one, get yours rebuilt by a reputable service, or find someone from here with a spare one.

Also, you can go ahead and install a 23 spline transmission, but there are a few things that have to be done for it to work completely perfect.

Mind mentioning a couple of those "things"? I'm unsure of how many are on this used one that I will rebuild, if I buy it.

 

[92EagleAWD]

If your planning on having your transmission rebuilt, it doesnt matter, the output shaft for the TC can be changed VERY easily, I had a 23 spline before a shift fork broke and took 2-3 gear with it, i found a 90 AWD tranny for cheap ($100) and switched the spline myself so i didnt have to buy a transfer case. If you switch to the 23 spline tranny you will either have to change to a 23 spline Transfer Case or switch the output shaft back to a 22 spline.

 

[1g_brandon]

the output shaft isnt a big deal. the shaft can be changed out for a 22 or 23 spline. all that is needed is unbolt the end cap on trans. then take off circlip that holds the viscous coupler on. then removed vc but watch out for the small ball in the shaft that the vc slides on to. once the ball is located put it somewhere safe and then you are able to pull output shaft out and replace it with another. make sure to put the ball back in because it secures the output shaft in the trans, when vc is reinstalled it keeps pressure up against the ball and in return holds the output shaft from coming out of trans. and also there is 2 holes in the shaft where the ball can go, iether hole will work it does not matter. i hope this helps i know i suck at explaining technical type stuff. i work on these trans quite a bit. some where good builds, some not so good. these trans are easy to work on, just rip it apart and start havin fun.

 

[Iheartboost]

If your planning on having your transmission rebuilt, it doesnt matter, the output shaft for the TC can be changed VERY easily, I had a 23 spline before a shift fork broke and took 2-3 gear with it, i found a 90 AWD tranny for cheap ($100) and switched the spline myself so i didnt have to buy a transfer case. If you switch to the 23 spline tranny you will either have to change to a 23 spline Transfer Case or switch the output shaft back to a 22 spline.

oh, right on, this should be cake , thanks!