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Date:         Thu, 3 Jun 2010 12:34:55 -0700
Reply-To:     Robert Fisher <garciasghostvw@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Robert Fisher <garciasghostvw@GMAIL.COM>
Subject:      Re: 2.1L engine failure - Update #2
In-Reply-To:  <01e801cb0351$0615fe10$6401a8c0@PROSPERITY>
Content-Type: text/plain; charset="US-ASCII"

I would still be concerned about the overall integrity of the piece. You could have the best welds in the world and it won't do much good if the metal around it is weakened/cracked. You might just set yourself up to go through the whole experience again. That's two big heavy chunks of metal held together in the middle by the four bolts on that housing. I think I'd can it and find myself a good used unit that was in one piece- in this case I think the devil you don't know might be better than the one you do know.

Cya, Robert

-----Original Message----- From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of Scott Daniel - Turbovans Sent: Thursday, June 03, 2010 12:15 PM To: vanagon@GERRY.VANAGON.COM Subject: Re: 2.1L engine failure - Update #2

hmmmm... I would say it will take very careful expert welding to get the bell housing repaired and dimensions still perfect on it - on a vanagon auto trans bell housing - which is not a separate bell housing - see below.

welding cast iron ... I had an expert welder freind weld a 1.6 TD block one time. First we heated it in a charcoal fire for several hours, he arc welded it with nickle rod I think, then we buried in it clean sand overnight for slow coooling, then I had to get the flywheel end of the block resurfaced by a maching shop. It was fine after that, and that engine ran for a long time...that incideent was one of 3 or 4 near death events that engine went through even ! ..lol.

My point is welding cast iron has to be done right.

The auto trans bell housing is not a separate bell housing. it's the main body of the auto trans. I have one here at my shop, with just one small piece broken out of the corner of one of those 'windows' around the torque converter area .. if anyone wants to do a whole trans number using this one, I would sell it. Would want the buyer to see pictures in advance.

but ...unless you have small cracks, that can be addressed with everything assembled... welding on a vanagon auto trans cast iron bell housing is a 'whole rebuild the trans' type of job.

Good welders don't weld on assembled oily things,. they weld on bone dry clean bare metal castings.

Scott www.turbovans.com

----- Original Message ----- From: "Frank Condelli" <RAlanen@AOL.COM> To: <vanagon@GERRY.VANAGON.COM> Sent: Thursday, June 03, 2010 3:01 AM Subject: Re: 2.1L engine failure - Update #2

> In a message dated 02/06/2010 1:43:54 P.M. Eastern Daylight Time, > LISTSERV@GERRY.VANAGON.COM writes: > > Jack, actually that's a very common problem. That flex plate VW > used is too weak. The only option is to find a good used one, inspect it > carefully to see that there are no cracks beginning around the hub. The > bell > housing should be easily repaired by any welder who can weld cast iron, > not a big problem. > > > >>>>>The mechanic pulled apart the motor / trans on our friends 90 Westy > 2.1, > discovered that the "flex plate"/ Fly wheel > blew up! Basically ruptured and caused everything to stop abruptly... > auto > trans bell-housing > cracked in 5 places, and needs a new Flex Plate. (anyone have a source > for > this?). > > Motor still turns, haven't tried to start it. > > They are quoting big bucks to change auto trans or weld bell housing, if > trans is OK. > > What could have caused the flex plate to break-up? > > Any suggestions on a course of action?<<<<<<< > > > > > > Cheers, > > Frank Condelli > Almonte, Ontario, Canada > '87 Westy & Lionel Trains (_Collection for sale_ > (http://frankcondelli.com/trainsal.htm) ) > _Frank Condelli & Associates_ (http://frankcondelli.com/busindex.html) - > Vanagon/Vanagon Westfalia Service in the Ottawa Valley > _Vanagon Stainless Steel Exhaust Systems_ > (http://frankcondelli.com/exhaust.htm) > _BusFusion_ (http://www.busfusion.com/) a VW Camper camping event, > Almonte, ON, June 10 ~ 13, 2010


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