Date: Thu, 5 Sep 1996 12:02:52 -0400 (EDT)
Sender: Vanagon Mailing List <vanagon@vanagon.com>
From: ERIC ZENO <emz@viper.nauticom.net>
Subject: Transmission R&R part 2
Part 2
Step 1 of repairing the clutch was to examine the throwout bearing,
pressure plate, disc, and flywheel. To my amazement I found all
the parts in new condition, covered in heavy black dirt.
Everything except the clutch disc. The disc was wrecked: high
R.P.M.'s tore it apart. As for the dirt, the last (jerk) mechanic
that was into the clutch (german motorwerks, here in Pittsburgh,
PA) didn't clean anything. So when the disc came apart it thru
dirt everywhere. Diagnosis was done, cleaning of the bell housing,
rust proofing, painting was next and the longest/hardest part.
I ordered the new disc, some stainless steel bolts and nuts for
the exhaust, and moved to the starter for a quick check. First
look, I found silicone seal, Rust, undercoating, and blistering
paint all over. It has 100,000 mile on it, I took a quick look
inside. This revealed a mess: burn't field windings, a hand full
of worn brush material, rust, etc. OK, Out to a Rebuilder it went.
$55 for complete rebuild. Not Bad! Cleaned the CV joints, painted the
shift rod, Transmission mounts. Closer inspection of the motor
(a GEX rebuild, as I was looking for a oil leak), I found the
rear oil sending unit wiring laying on the exhaust and the insulation
burn't off. (another jerk mechanic created problem). Fixing the
wire was easy. Getting it away from the exhaust wasn't. Ended up
removing the exhaust head pipes. This revailed a crack in the front
Pipe, and a stripped thread in the head for the rear pipe. Well...
The crack can be a matieral problem, then I realized that my other
Vanagon has a support in center under the motor. I bet that's the
reason it cracked. For the Threads that are stripped....Well I just
cann't believe these mechanics are still in buissness! I welded
the exhaust and cleaned the threads out of the stripped hole.
I lucked out. These holes in the heads are very deep. With a much
longer threads than needed. It looks like I can get plenty of
thread and install a longer bolt.
Next: part 3 - installation - To night.
Eric Zeno
emz@nauticom.net
86 Syncro
86 GL
72 240Z
1936 Chrysler
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