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Revised January 19th, 2012
Fact Sheet - IRS I Conversion Kit
Owners of Buses can now remove those sometimes unreliable reduction gear boxes and obtain engine-saving highway gearing. In addition, your Bus can now have the wide range of aftermarket gear selection with this kit, as well as the advantages of Independent Rear Suspension that allows your Bus to handle even better than before. The basic bolt-on kit comes with our specially made Control Arm Brackets Clamps, CV Axles, Spring Plates, Hardware, Nosecone Gasket and complete instructions necessary for this conversion. This kit does lower the rear end of your Bus at least 1 inch, but can be safely lowered to a full 4 inches below stock height. In some cases, you can even go down as much as 6 inches. So to fully appreciate the benefits of this conversion, our adjustable beam is strongly recommended so that your ride is fully level. This particular IRS Kit for the pre 68 Bus has proven to be a very popular, reliable conversion since our introduction in 1988.
An IRS Transmission from a 69-79 Bug or Super Beetle is required for this conversion. To properly mount this transmission in your Bus, your old nosecone and nosecone shift rod (the hockey stick) only needs to be swapped to the IRS transmission. If you have a 56-Early 59 Bus, our Transaxle Front Adaptor Mount will also be needed as the front mounting system used on these years will not work with the Late 59-67 Bus nosecone required. If you need them, the adaptor, nosecone and hockey stick are shown in our parts list below on this page.
Unlike other conversions that can be done by the do-it-yourselfer, we supply CV Axles specially made for this conversion. These are called floating axles, which means the splines are extra long and allows the axle to "float" within the CV joint. We have found that this design is much easier on the CV joints, as it does not allow the joint to "bind", which can be a real bummer when heading down the highway, taking a sharp corner or going over speed bumps. Other conversions we've seen have the late Bus CV Axles machined down and shortened, which does not leave much splined surface for the CV joints to ride in while the axle moves back and forth. In addition, our axles come with the necessary spring clips to prevent the CV joints from sliding too far off the end of the axle shaft.
CV joints from a 69-79 Bug or 69-73 Type 3 are used in this conversion, if the rear end is lowered more than 3 inches. If the rear end is 1 to 2 1/2 inches below stock height, the axle shaft can become angled too far to allow these CV joints to work properly. Bug and Type 3 Joints have a limit of 16 degrees of maximum angle before the inner CV cage can possibly come out. To correct this problem, we recommend the installation of Modified CV Flanges on the Transaxle, Modified Axle Stubs on the IRS Control Arms and Type 4 CV joints both inside and outside on the axle shafts. These axle stubs and inner CV flanges are similar to what is used on the Type 181 "Thing" and will work with the IRS Control Arms used in this kit. Type 4 CV joints have a maximum working angle of 22 degrees. A little more expensive, but worth it in the long run. None of these items are included in the kit, but they are separately available in the parts list further down on this page.
This kit is designed to utilize the IRS Control Arms from a 72-79 Bug or Super Beetle. These are not included in the kit, but are available from your local VW Auto Parts Recycler at a reasonable cost. While you're at it, be sure to get the axle stub and wheel bearings, if they're in reuseable shape - you'll need these too. 69-71 IRS Control Arms are not useable with this kit, due to the design of our spring plates (these arms utilized a "dual" spring plate). Besides, the supply of 72-79 Control Arms are much more plentiful.
The kit shown here comes with NEW Non-Adjustable spring plates that are precision cut to allow proper torsion clearance. Adjustable Plates are also available, allowing you to "fine-tune" your height to your desires. Our redesign now incorporates a outer "notch" so that a flop-stop (as shown in the old picture above) is no longer required. We've seen a lot of "home-brew" modified plates and some from other competitors trying to imitate our kit. We feel some of these are cut improperly or have very sloppy workmanship that give us pause as to the long-term reliability. Like we say, why fool with imitations when you can have the original?
For Buses made through 1963, you can use your original drums. The drum must be slightly modified to accommodate the rear axle shaft and for the axle nut to tighten properly. This is explained in the instructions provided.
For Buses made from 64 through 67, you cannot use your original drums, backing plates or shoes. You must make the following choices:
A. Install 5 Lug Drums from a 56-63 Bus. Drum must be modified as explained above for
the pre 64 models.
B. Install 5 Lug Drums, Shoes and Backing Plates from a 64-65 Type 3 Notch or Squareback.
This is highly recommended as the drums and shoes are close to the same size as your
originals. The only drawback to this is the scarcity and high price of these drums.
C. Install 4 Lug Drums, Shoes and Backing Plates from either a 68-79 Bug or a 68-73 Type
3. The drawback to this is that adaptors must be used to convert back to the large 5 Lug
Pattern. There is one advantage to using 4 Lug Bug Drums and that is that they can be
re-drilled for the smaller Porsche 5 Lug Pattern if you're using Porsche Style Alloy
Wheels.
The conversion kit is provided with special-length tubes to "extend" the cable cover/tube to compensate for the spring length on the end into your brake backing plates. This applies only to 64-67 with stock cables. On Late 60 through 63 models, you must upgrade to the 64-67 style cables and use the extension tubes as well. 56 to Early 60 models will have to modify and upgrade to at least the Late 60 through 63 or 64-67 Hand Brake system, including cables to retain Hand Brake use.
210-51012 IRS Axle I Kit - Non Adjustable $530.95
210-51012A IRS Axle I Kit - Adjustable $639.00
210-30001 Front Trans Adaptor Mount (Required for 56-Early 59 Buses) $35.95
211-301-205H New Front Nosecone Late 59-67 (This nosecone requires 211-301-265A Front Mount) $66.80
113-301-263 Rear Trans Mount Left/Right $4.45 each
211-301-265 Front Trans Mount Late 59-62 $9.95
211-301-265A Front Trans Mount 63-67 $23.45
113-501-331 CV Joint - Inner/Outer - Bug Style $56.50 each
191-498-201DZ CV Boot Kit w/Clamp/Grease (For Bug Style CV Joints Above) $6.35 kit
113-501-331D CV Joint - Inner/Outer - Type 4 $106.00 each
251-598-201 CV Boot Kit w/Clamp/Grease (For Type 4 Style CV Joints Above) $18.25 kit
113-501-229C Bolt for CV Joint - 6 per joint req. $0.50 each
113-501-229D Bolt for CV Joint, Type 4 - 6 per joint req. $0.50 each
NOTE: Must use an 8mm allen wrench with 113-501-229D
113-517-283AU Inner CV Flange for Type 4 Joint, Used $50.00 each
113-517-283AZ Inner CV Flange for Type 4 Joint, New $90.85 Pair
181-501-263Z Outer CV Flange/Axle Stub for Type 4 Joint $90.00 each
NOTE: 181-501-263Z are sold exchange - $60.00 Core Charge per Axle Stub extra.
113-501-231 Outer CV Flange/Axle Stub for Bug CV Joint (New) $105.95ea OR Used $35.00 each
311-501-221 Rear Axle Nut $8.00 each
N 12548.1 Cotter Pin for Axle Nut $0.25 each
113-501-283 Inner Rear Wheel Bearing (FAG/SKF) $11.80 each
113-501-277A Outer Rear Wheel Bearing (FAG/SKF) $32.35 each
113-501-315G Rear Wheel Seal - Inner or Outer $2.25 each
113-501-615J Rear Drum - 4 Lug Bug (New) $29.95 each
311-501-615F Rear Drum - 4 Lug Type 3 (New) $49.00 each
311-501-615E Rear Drum - 5 Lug Type 3 (New) $110.00 each
311-501-581U Rear Hub for Type 3 4 Lug Drum (Used) $15.00 each
113-609-537J Rear Brake Shoes Bug 68-79 $22.47 set
311-609-537E Rear Brake Shoes Type 3 64-73 $34.20 set
ZAP-41312A KYB Gas-A-Just Shocks (Special Modified For Lowered Applications) $67.00 each
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