Date: Wed, 11 Mar 2009 08:55:55 -0700
Reply-To: aatransaxle <daryl@AATRANSAXLE.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: aatransaxle <daryl@AATRANSAXLE.COM>
Subject: Re: Mostly successful manual trans replacement
Content-Type: text/plain; format=flowed; charset="iso-8859-1";
reply-type=response
Ed..The old backup switches are NLA so the newer style it all there is.
Get some narrow connectores from your FLAPS and repl the ends of the wires
with them.
Daryl of AA Transaxle
(425) 788-4070
aatransaxle.com
86 Syncro Westy
Zetec in the trunk
----- Original Message -----
From: "Edward Duntz" <eduntz@HOTMAIL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tuesday, March 10, 2009 9:52 PM
Subject: Mostly successful manual trans replacement
> 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
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