Date: Mon, 14 Dec 2020 20:17:57 -0600
Reply-To: "Jim. Felder" <jim.felder@GMAIL.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: "Jim. Felder" <jim.felder@GMAIL.COM>
Subject: Re: Difficulty / time to replace clutch - 1991 Westfalia 2WD
In-Reply-To: <c9b72e2d-6fa7-cf29-31ea-af39b3f748cb@williamsitconsulting.com>
Content-Type: text/plain; charset="utf-8"
It isn’t a hard job. You can support the engine with a chain hoist on a saw horse and pull the transmission out with a buddy to help. Or a transmission jack. Replacing the clutch requires removal of the clutch pressure plate. Remove all the bolts around it few turns at a time in sequence so as not to distort the pressure plate as it is under spring pressure. When you order your replacement disc, be sure to get an alignment tool for it. If you go to bolt the transmission back in and the disc is not aligned with the pilot bearing you will have to drop the transmission again and do the alignment ov r until it works.
This is the time to pop in a new clutch release bearing. While it is out it is time to replace the transmission shaft seal, where you have to work the old one out and hammer a new one in with a pipe that will engage it. And oh, yeah, you absolutely must rent a puller or buy a tap to put threads in the roller bearing up in the end of the crank. Then you have to carefully drive the new one in before refitting the transmission.
Getting the engine out of the car is not as easy as dropping the transmission, but at least you get to do all that ancillary stuff on your workbench instead of under the car.
Best of all and fairly easy is dropping engine and transmission together by loosening the moustach bar and the front transmission mount—plus the other obvious stuff and hoses—from the car. That way you get to refit the transmission to the engine in the floor of your garage. But be warned that to clear the thermostat housing clear of the body you’ve got to get about. 28 inches of clearance somehow, which is not easy and not altogether safe with ordinary equipment.
Good luck,
Jim
>
> On Dec 14, 2020 at 7:45 PM, <Steve Williams (mailto:steve@williamsitconsulting.com)> wrote:
>
>
>
> Hi,
>
> My clutch is on it's last legs. I can smell a very slight burning smell
> after pulling some long mountain hills in 3rd gear.
>
> I've done most of the mechanic work on my van, CV's, full coolant system
> upgrade (hoses, pipes, etc) and have done engine work on previous
> vehicles I've owned.
>
> The only major work I haven't undertaken myself was a recent complete
> exhaust system replacement with all the rusted studs / nuts & bolts :D.
>
> How difficult would it be to undertake replacing my clutch on my own?Â
> I've got lots of time, a heated garage but no lift. I assume I'd be
> doing a lot of the work laying on my back.
>
> Is this one of those jobs I should just pay a shop to do? I've got a
> very good mechanic to use where I live. What would be a reasonable
> number of hours for an experienced Vanagon mechanic to replace the
> clutch? How about an inexperienced DIY'er? lol.
>
> Thanks,
> Steve W.
>
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