VW Self Machine Syndrome

VW's Self Machine Syndrome Explained
Below is a bit of info. on the dreaded VW "self-machine" problem. From our point of view there are three reasons for this condition. These three problems stem from the use of rivets to hold the ring gear to the carrier. The ring gear being the biggest gear in the gearbox-driving the carrier (which drives the axles hence trans"axle"). These rivets must endure all the torque the engine puts out + the multiplication of torque by gear reduction. The most common gear box runs a 3.67 final drive with a 3.45 1st gear. If an engine puts out 125 foot pounds of torque 125 X 3.45 x 3.67 = 1582 Foot pounds of torque. That's lot not including shocking the system by side stepping the clutch and other abuses.

First is the extended rivets VW used in lieu of cir-clips on the cross-shaft.The rivet head wears by constant cycles of the cross-shaft striking it. This allows the cross-shaft to plow a furrow in the case and eventually a hole.
Next VW added clips to the cross-shaft. They continue to use rivets to secure the ring gear to the carrier. The extended rivets sheer off with no warning and circulate in the gear box to eventually find their way to daylight. This is the most common failure.
Third the flat rivets sheer and with no warning. They usually run between the ring and pinion before spitting through the case.


4spd & Early 5spd Note all rivets are flat. We really hardly see a problem with these. They are really tuff to remove once drilled.	'84 & Later 5Spd Note one broken extended rivet at end of cross-shaft. Flat and extended rivets are now softer and press out much easier than their early cousins..


One broken extended rivet (9:00). The cross-shaft was retained. Thanks to the cir-clips. But the rest of the transaxle was scrapped.	Two flat rivets at 6 & 7 o'clock are snapped. No holes in the case but lots of speed gear damage.


BIG HOLE 16V POWER!!You know who you are-always the biggest hole.	Mark III Jetta with 75K. Correct they still haven't fixed the problem. '95-'84=11 YEARS!

Classic job- no cir-clips nice small hole.

The cure a simple $35.00 Bolt Kit