Date:         Tue, 10 Mar 2009 23:52:18 -0500
Reply-To:     Edward Duntz <eduntz@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Edward Duntz <eduntz@HOTMAIL.COM>
Subject:      Mostly successful manual trans replacement
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Thanks to everyone who sent procedures and advice. My replacement manual
transmission (reportedly recently rebuilt) went in the '85 today. With the
help of my father and his friend's lift, it wasn't too bad. About seven
hours including some standing arouind time. Here are the things that were
most difficult:

A little hard to maneuver, but not too bad. Van was on a drive-on lift, with
braces across with jacks for the engine and trans.

As many have discussed today, the clutch lever was very difficult to get off
the shaft. Using levers and pullers did nothing. My father's friend got it
red hot with a welding torch and it finally came off. It bent the cross
shaft, but fortunately we weren't re-using it- it was on the replacement
trans.

Upper starter bolt was a pain, but do-able.

Forgot to check on starter bushing. Peeked back in and didn't see one, but
didn't want to hold things up on re-assembly. I think it can live without
one for a while, and will pull starter and install bushing later.

Reverse light switch on new trans was slightly different. Old one had bare
terminals, and a "normal/large" size. New one had plastic surrounding
smaller terminals, which the old wires/terminals wouldn't have fit. Re-used
old switch, which was working fine. But now back-up lights are on all the
time. Was too late in the evening to diagnose, so pulled a wire off the
switch. Will check operation of switch and go from there.

All in all, wasn't too bad. Glad I did it and saved money over a
professional mechanic. If I had good garage spaceof my own, I might try
more. May have to replace engine with good used one in the next year or two-
might try that, too.

Ed in CT