Date: Wed, 11 Mar 2009 12:31:05 -0700
Reply-To: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: Scott Daniel - Turbovans <scottdaniel@TURBOVANS.COM>
Subject: Re: Mostly successful manual trans replacement
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reply-type=response
if there was no starter bushing in the bell housing......
you'd know it. without that part the starter teeth could easily strip or
skip on the flywheel teeth.
There's probably a starter bushing in there.
I don't find that they wear much at all really, not enough to be a problem
for a long, long time usually.
See how thick the washer is on your back up light switch. If it doesn't
screw in far enough, or has too thin a washer and it goes in too far, you
can end up with back up lights all the time, or no back up lights ever,
depending.
scott
turbovans
personally, I find working on a van with it a foot and a half or so off the
ground, to be considerably easier than working on one on a lift.
----- 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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