Date:         Thu, 27 Jul 2006 17:46:45 -0400
Reply-To:     Roger Sisler <rogersisler2000@YAHOO.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Roger Sisler <rogersisler2000@YAHOO.COM>
Subject:      Re: clutch housling rebuil

Sorry this proceedure is so broken up. I have just learned how to send
photos to vanagon list. Not too good at it so far. Any way ,"what hast god
wrought?". Me with a camera?

The Vanagon clutch housing repair is not common in the archives. Most folks
want to replace the drivers side clutch operating shaft(cos) because of
damage  while trying to remove the slave cylinder mount.This discription
will show most aspects of this proceedure.

New parts are avaliable.However,the plastic sleave/bearing from VW, is now
a 1 piece ,combined unit. VW dealers show this as being a discontinued
item. Rick at BD  found it for me. It should be discontinued. Heavy duty
pressure plates were not avaliable for the Vanagon ,when first
manufactured. They were not avaliable new. Today ,many folks want  heavy
duty clutches, to avoid vanagon clutch chatter. This heavy pressure plate
will destory the plastic drivers side cos bearing.

I found a preformance driver side cos bering at Rancho transmissions, in
California.Rancho  rebuilds BD  transmissions. It costs less than the
origional Vw bearing. This new bearing is a heavy brass unit. The inside is
honed for grease retention.NO seals are used,nor needed,according to
Rancho. They last a long time, with out failure.

Installation is EZ. I used a spark plug socket to drive it in,or should I
say ,tap it in. Important,is to line the 11mm holding bolt hole
up,first.This 11mnm bolt has a guide pin on it's end to help do this.EZ,EZ

The passengers side is still an origional VW bearing and is a fine unit. It
has dimples on the inside to hold the grease. I first got a non origional
replacement bearing,because I could not find the correct one. It was a
Brazillian bearing,without dimples.I sent it back.

Removal of this bearing ,and it's replacement requires special tools. Not
VW tools, but Auto Zone special loaner tools. Specificaly a blind hole
bearing remover,and a bushing driver. Perhaps the bushing driver is not
necessary,but why delet it? EZ in and out.

The seal was replaced while I was at it. I used a 11/4 inch deep socket as
a driver for the seal.This is a VW origional seal. Part 113311113A. Got to
go now.I will complete this later.Roger