Date:         Thu, 5 Feb 2004 19:43:18 -0500
Reply-To:     Jim Huskins <lostranger@MINDSPRING.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jim Huskins <lostranger@MINDSPRING.COM>
Subject:      Report on A/T rebuild
In-Reply-To:  <005501c3ebf7$9aaa3000$ba62fea9@oemcomputer>
Content-Type: text/plain; charset=US-ASCII; format=flowed

About a month ago I asked the list for advice on rebuilding the
transmission in my "new" '91 Carat. I received a lot of information,
and it led me to decide to do the work myself. As of today, the van is
on the road again, and I'm happy with the choices I made.

I've done lots of other mechanical work over the past several decades,
but this was my first automatic transmission rebuild of any variety.
This project involved several repairs which I believe to be beyond the
scope of a "normal" rebuild. I had a bad planetary and a broken
diaphragm spring. The final drive case was very rusty. The throttle
cable connector was frozen to the kickdown lever. The throttle push rod
would not come loose without a torch, and that destroyed the plastic
bushing. I ended up making a new one from a bronze starter bushing.

Doing the work myself allowed me to correct all these problems without
being at the mercy of any shop. It also allowed me to get both cases
really clean and do it on my own schedule. I'm already stocking parts
to rebuild my daughter's '88 Wolfsburg.

The transmission works wonderfully, I saved at least a thousand bucks,
and I know what was done and how. The down side is that the car was VOR
for a month, mostly because I had to keep locating and waiting for
additional parts. I'll probably buy a core and build it while Daughter
is still using her van.

Thanks to all who contributed information.

Jim Huskins
Spruce Pine, NC