how much oil in 091 transmission

[stu817]

Ok here is the problem I bought a six rib 091 transaxel from a guy that was going to build a buggy.He said he had brought it to a vw shop and had the transaxel inspected and resealed it came with no oil in it.When I was ready to install this in my buggy I changed the bellhousing and trimed the shaft to fit my 1600. When I had the bellhousing off and could see the ring and pinion in it was real clean I also took off the nose cone and replaced the shift ball with a steel one,all was clean and in good shape.I also filled it with penzoil 80 90 gear oil It looked almost new.So now that the trans is mounted and I fired it up had to adjust the clutch a little tested all the gears it went into all gears great felt good so I pulled it out of the shop and went on a test lap around the parking lot and the only problem that I have is a whine noise from trans only when under load 1st through 4th it is not there if you let off on the gas  not real loud but a little concerning.So I am wondering if first could the trans be under filled and how much oil woud be in this trans I put in 3.8L untill it was comming back out the hole.I was wondering if maybe I just filled it to fast and did not fill it enough this will be the first thing i will check in the morning.
The other two resons that I can think of is a slim chance that my mod on the shaft is wrong but not likly my machinist friend and I did it together useing the old bug trans as a sample and some good micromiters aprox 1/2" off the end and new taper aprox 1/2" the other is maybe it was not put together right.
Could it be making noise if thay put any new parts in it ,probably not I am shure the old owner would have told me but have to ask everyone and cover all my bases  
Now am I just over reacting with this probably not but just dont want to cause more damage


Thanks for the help

[Chris]

New throwout bearing?

[stu817]

new clutch and throwout bearing 1700lb kenady could it be clutch adjusted too tight

[BUSDADDY]

Clutch and throwout wouldn't make noise driving unless the cable was way tight, but then it'd make the same noise sitting still in neutral.
Yank and push on the rear pulley and see if the engine has any endplay, if it doesn't move the shaft may still be too long.

[stu817]

I  just checked the end play with a dial indicator it is .006 so there is a bit of movement I also looked at the type of oil that I put in it and it is penzoil 89/90 gear plus the back of the bottle states it is a 5

[stu817]

I forgot to post that the trans is solid mounted and I talked to cal import about this today and they said that it could just be this.I am going to try and drive it and see if it gets worse but would still like your opinions

thanks

[stu817]

I decided to call a company called german transaxel 1 800 892 4327 for advice he has alot of experiance with 091 trans he said it just sounds like main bearing so I will pull it back out and take a look he also said that only use gl4 oil and it holds 3.5 L

[Chris]

this is a rail or a dune buggy? I dont think that your going to get the noise from solid mounting the tranny, unless its a complete car and even then my car without an interior doesnt whine like your describing.

[stu817]

this is in a manx  with a coustom aluminum floor pan using the tungle and horns from a beetle

[Bruce]

he aso said that only use gl4 oil ....

The guy's a 'tard.
Your 091 gearbox has a hypoid ring and pinion.  Because of this, you need the higher extreme pressure rating of a GL-5 oil like you have in it now.  Using GL-4 will burn up your R&P.  According to Dave Folts, this is the #1 cause of failure of Bus 'boxes.  It's so common, he won't accept a core until he pulls the bell housing off for an inspection.

[Bruce]

.... it just sounds like main bearing ..

There are 2 bearings on the mainshaft.  One on each end.  Because of this, they make noise only when you're in the gear adjacent to the bearing.  IOW, if it makes noise in all gears, it's not the mainshaft bearing.

[stu817]

all good advice  I woud like it if someone with knowledge on this transaxel would come out and have a look and listen.It would be good if he had the ability to fix it or take it and rebuild it if it needs to be. If anyone knows someone like this could you pm me. I am going out of town for two weeks but will have my computer with me

thanks for the help    (still confused)

[stu817]

I found this site it has all the spec for 77 bus inc the trans fluid        http://www.type2.com/
this site has alot of good info