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Tops on the list is the reverse gear.Fallowed closely by the keyed gears.Third would be the case.
I would have to agree that reverse is the weakest but the next thing that usually lets go in one of these is second. That is because most off road vehicles are in second 85% of the time. There are no keyways in these or any 091. The keyed fourth went away in the last years of the swingaxles and the one on the mainshaft that drives 3-4 was changed to a spline 4 years before the 091 went into production. We don't see many case failures in the bus. The biggest advantage of the aluminium case is it is much more rigid and will keep the ring&pinion alive longer.If you can use a stock geared bus then this is a good deal. The guy's at Weddle are awesome! I've dealt with them for 25 years. Straight shooters! These trannies were used in buses that came with either a water cooled diesel or a rabbit/jetta type engine that made between 50 and 100 HP.If you want to use them as a starting point for a high performance trans then they are not such a deal. The 457 ring&pinion is noticeably stronger,you need to change all the gears and add a 4 spider diff with chromoly cover,and you need a bellhousing and input shaft(assuming your not making something totally custom like Masterfabr). So you end up only using the case,intermediate housing,nosecone and stock stuff like bearings,syncros,forks. All good quality stuff but you will have paid a premium for it.
No but I would throw in a magnesium one if someone wanted one
A brand new aluminium case is $600