Date:         Wed, 10 Nov 2004 16:54:40 -0500
Reply-To:     Mike Collum <collum@VERIZON.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Mike Collum <collum@VERIZON.NET>
Subject:      Re: Stuck in 4th - Final Answer + more questions

This summer, just prior to a trip from Maine to Virginia, I pulled the
transmission out of my '85 Westy and replaced the crankshaft mainseal, pilot
bearing, felt washer, clutch disk and pressure plate, throwout bearing,
clutch actuating lever bushings, starter bushing, and transmission input
shaft among other things.  This was my first time to pull a Vanagon tranny
and I did the in/out and repairs without assistance.  I only pulled the
transmission.  I did NOT pull the engine.

This was done in my driveway which has a hardpack surface .... dirt and
gravel.

I do not have a transmission jack but I do have a 3 ton and a 2 ton garage
style jack and jack stands.  When putting the tranny back in, I started it
up on the smaller jack but saw that, without assistance, it was going to be
unwieldly, so I got a number of pieces of scrap wood (3/4 inch thick squares
which had been cut from planks) and lifted the tranny with one hand while
slipping another piece under until I had the correct angle and pushed it
right back in place.  No problems.

BTW ... I'm 62 years old and not quite as strong as I once was, but
manhandling the tranny was no big deal.


Some good info can be found here:  http://volksweb.relitech.com/clutch.htm
It addresses removing the transmission.  The only thing not mentioned that
is required is disconnecting the throttle cable from the bracket on the
transmission housing.

Mike
'84 GL 7 pass
'85 GL Westy

<snip>
You can pull the engine by itself, but to pull the transmission you need to
pull the engine to get it out of the way.  Depending on the shop will depend
on how it gets booked and you can get ripped.

A shop that does it nicely will only bill for slightly higher than just an
engine pull because they will pull the engine and transmission as one unit
and then detach the transmission so there is only a slight difference in the
actual labor time.  Others will bill for the individual rr rates which is
way higher.

As for doing it yourself, it is not that difficult

Remove battery cable from pos term
Remove alternator wiring
Remove fuel line and plug
Remove fuel return and plug
Detach vac line for brakes and plug
For water boxer get large coolant drain pan and pull off lowest hose to
drain coolant
Remove other hoses as needed and mark where they were if not obvious.
There will be other wiring to disconnect as well.


Two bolts on right frame and on left frame
And the transmission mount bolt
And the hydraulic line to the slave cylinder on the transmission.

A jack or some kind of platform to lower the tran/engine to is going to be
needed.  For a connected unit I usually lower from the top down to a sheet
of plywood and then pull the sheet out from under the vehicle with
everything on it.

NOTE...this is just a quickie sketch and not a full procedure!!!
<snip>