Date:         Fri, 28 Jul 2006 11:12:33 -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 housing rebuild

The clutch operating shaft (cos) is avaliable new from most venders. It
costs about $20. The one you see here is from BD.

 I have removed the clutch arm from three cos. Two came off fine,but the
third required dynamite. Place a screrw driver edgewise between the case
and slave cylinder mount.Not the case and clutch arm,or smount and clutch
arm.. When driving with the screw driver, the force will press on the mount
and remove the clutch arm. If repeated hammers wont budge the arm,be
prepared to saw the shaft in half. Sawing the shaft is not as difficult
asit sounds. The steel is the softest I have ever seen.One Chinese hack saw
blade cut it in minutes without sweat. One picture shows the cut steel
piece with a 1/2 inch hole drilled into it. It took a press to get the
piece of steel out of the clutch arm even after I hacksawed it.  Like I
say, the other two were gravy.

I think the new brass Rancho bearing can be installed with the trans in the
vehicle. If the plastic sleave and plastic oem bearing can be removed,that
is. I removed my ,withthe trans out of thevehicle. I backed off the snap
ring and washer that stop the bearing on the inside. I let the cos press
against the plastic sleave that shows onteh inside. I hit it many times
with a hanmmer and it drove out to the outside.I then grabbed it with a
plyer and pulled it the rest of the way out.If you can do this from the
outside,the trans dosent need ot be removed. When driving the new bearing
in, It will stop when it meets the washer and snap ring.Also,the hole for
the 11mmbolt should be lined up at this time.

The passenger side bearing uses a blind hole bearing extracter. It is a
slide hammer thing with expanding jaws on the end.this bearing is very ez
to remove,but may not need it. The bearings I removed were ok,with only a
few deep scratches. Still,Idid it to know for sure ,it is a complete job.

The cos of all vehicles had lots of pitting and corrosion on the area where
the seals and bearing meet. see the pictures. This is another reason to
replace the shaft.Be sure to grease each bearing before assembely.This is
all the grease they will ever get.