Date:         Thu, 19 Dec 2002 18:10:25 -0800
Reply-To:     Michael Snow <mwsnow@COX.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Michael Snow <mwsnow@COX.NET>
Subject:      Re: Trip Report: 742 miles and a blown seal
In-Reply-To:  <BA2776A2.4930%jrunberg@mac.com>
Content-Type: text/plain; charset=us-ascii; format=flowed

john runberg wrote:
> Just took the new-to-me Vanagon diesel on a trip into the mountains for
> business and am glad to say I made it home - barely.
>
> The trip was from Virginia Beach to Blacksburg (both in Virginia) and I got
> to go over one of the steeper mountain passes in the state. The van did OK -
> better than I expected - only slowing to about 45 on the steepest climb.
>
> Wasn't expecting to have to drive the diesel, but the Carat sprung another
> leak which I haven't fixed yet. Combine that w/ it's noisy/scary tranny and
> I don't feel so good about long trips. My new tranny from will fix that once
> installed. Although the diesel had problems, it did average 32mpg with an
> average speed of 53mph. Nice.
>
> The good: Maybe I'm the only one, but the Carat seats that I put in this van
> are super-comfy. They made the 7hr drive not only bearable, but enjoyable as
> well. I can't drive more than an hour in the Jetta without butt pain.
>
> I got there, and got home. I even was able to drive a consultant to the
> airport (who actually got a kick out of it).
>
> The bad: Spattered oil all over the back hatch from a missing o-ring on the
> dip-stick hole. Whatta mess. Quick fix with strategically placed duct tape
> to hold it tight in there and it was better on the way home. What's the best
> way to clean this?

I wish I knew the way to clean it.  Both of my diesel vans have
oil-stained paint on the rear hatch.  I'm pretty sure that anything that
will really get the oil off will take the paint with it.  Buy the o-ring
from the VW dealer.  I spent way too much time looking for a generic
o-ring in hardware stores.  Mine still leaks.
>
> Air bubbles in the system meant no heat most of the time. COLD drive in a
> giant noisy box. Didn't help that the interior had been pulled to clean it
> so what little insulation there was spent the trip in my garage!
>
> Noticed oil on the ground before beginning to head home. The clutch
> chattered a bit previously so I assumed I was getting oil in there, but this
> was the first time I saw oil on the ground. Checked the reserve supply of
> oil and headed out. Stopped halfway across the mountains and noticed a 8"
> puddle after only getting a drink. Out come the nerves. Top up and begin
> praying. Nothing happens for the next several hundred miles until I get off
> the interstate and come to my first light. SEVERE chatter coming away from
> the light. Second light is the same thing, but this time 4th slips unless
> I'm careful. At this point I'm so happy I made it this far I'm fine with it
> just giving up and me walking home (probably warmer that way, too), but I
> make it home and slide it into it's spot in the driveway. Go in, say hello,
> and come out to a 12" puddle. I think I have a leak.
>
> So how hard is it to change this seal? I assume the clutch is history as
> well, or can it be salvaged?

The clutch is probably junk.  The seal is easy to change, once the
transmission and flywheel are removed.  While you're in there, it's
worth the time and expense to change the transmission input shaft seal.
    The new clutch should come with a throwout bearing (I have only used
Sachs).  Also check the clutch lever for even wear on both "fingers"
where they support the throwout bearing.  Uneven wear leads to premature
failure of the bearing and broken clutch springs.  Check the clutch
lever bushings for wear and replace as necessary.  It's enough of a pain
to do this that you want to replace all of the "wear components" while
you have the transmission separated from the engine.  If you don't have
a Bentley manual yet, get one now :-)

Mike Snow
1982 Westfalia diesel 5 speed
1983 ASI diesel