TheSamba.com :: View topic

Sat Jul 19, 2008 9:45 am

I'm pulling the transmission this weekend for a rebuild. So, while it's out, what other maintenance tasks should I take care of?

Sat Jul 19, 2008 10:16 am

Pull the input shaft seal and make sure the oil slinger behind it is a press fit into the bell housing. Replace the seal. Make sure the throw out lever arms are the same length. It's a great time for a clutch if that is in question. Checking the pilot bearing in the end of the crank would be wise and the rear main seal if it is leaking. It will also be much easier to replace the drive flange seals and shifter seal if needed. Also, a good time to service the CV joints and boots.

Andrew

Sat Jul 19, 2008 10:50 am

Check for excessive play in cross shaft. If too much play, likely this is at the d-side. If cross shaft ok, replacing bushing(s) (I can't recall if there are 2) on d-side isn't *too* hard but it requires removing the clutch operating arm which is usually stuck on real good. i.e. possibly a PITA to remove. If you do this, be mindful of the bolt holding the bushing(s) in place. Bushing(s) has a hole that lines up with bolt end. DON'T over torque it! Mine was messed up. Had to make a new one and tap housing. Replacing P-side bushing requires a proper puller.

Check that throwout tube is on right. On mine, a bolt was stripped. Had to tap this too. I didn't enjoy the tapping! ;) Again these are a LOW torque value.

If cross shaft/bushings ok, squeeze in some lube. Especially to p-side bearing. You won't be able to add much, but slide the shaft over and lube it with grease. It doesn't see the light of day, so nows a good time to lube it.

I would suggest replacing the pilot bearing. I agree with Andrew. Inspect it for sure. But if it was me, I'd replace it regardless :) (though can also be a minor PITA to remove)

Sun Jul 20, 2008 4:45 pm

Uh, thanks. :shock: The last one kind of flew over my head. :cry: I'm a bit new to this game, so the jargon has thrown me. I tried looking for the "cross shaft" in the Bentley manual, but didn't find anything. Would you mind clarifying for a newbie? Is it the shaft that pushes against the clutch to disengage the drive shaft from the transmission?
Wow, I'm must sound daft. :oops:
Also, what's an "oil slinger"?

Thanks,
Mike

Sun Jul 20, 2008 6:18 pm

There is a plastic coolant tower to the right of the transmission. It's easier to replace with the tranny out. If yours is original, replace it. I cracked mine when I was replacing the clutch. The plastic gets old and brittle. Replacing it in the shop is easy, fixing it on the road is not.

http://www.van-cafe.com/vanagon_parts.jsp?pa=p&p=1917347128&pct=897933764&ct=910822852

Sun Jul 20, 2008 7:05 pm

The cross shaft is the rod with the two ears on it. the part the throwout bearing rides on gets flat wear spots on it. The bushings that hold it in place are plastic and rubber. So if you judge the condition of other rubber parts on the van, you can draw a conclusion on them. The pilot bearing is the tiny bearing that sits in the crank shaft that the transmission output shafts rests on. It needs a special tool, or magical powers, to remove. Luckily, Auozone will loan the tool for free with a deposit.

The basic philosphy is:
If your tranny is out, spring for a complete clutch kit. Pressure plate, clutch, throwout bearing and pilot bearing. The flywheel needs to be re-surfaced by a tranny shop or automotive machine shop before you put it back together. Cost is $30-$50 for the work. The other parts, like the cross shaft and bushings are other parts that wear and cause weirdness in your clutch system.

Decide how much your time is worth. Then throw as much as you can afford at the clutch system. Saves you from spending time gazing at the bottom side of your Vanaon.

Sun Jul 20, 2008 7:43 pm

Van called Finally.

I hope I wasn't too intense with my, uh, insights. ;)

And before I got my Westy, I had no idea what the term "cross shaft" meant. :)

In my case, I started hearing a clicking noise when depressing clutch. I determined it was a worn bushing. So, I "went to town" rebuilding my clutch housing since I was in there dealing with a worn bushing. I don't regret it. The "click" is gone. But please bear in mind that I tend to do "preemptive strikes" in regards to maintenance and repairs.

My point: your clutch housing parts may be perfectly fine. It's not hard to check. And as the saying goes: "If it ain't broke..."

Neil.

Sun Jul 20, 2008 8:13 pm

I'm installing my rebuilt motor tomorrow with new clucth, to bearing, input shaft seal and pilot bearing.

I haven't looked at the cross shaft yet but would like to rebush/replace if necessary. Is it the same as type 2?? Would the bushing kit be the same as type 2? I also have a syncro, shouldn't make a difference?

Sun Jul 20, 2008 8:16 pm

As for the part being the same, other wiser folks with a cross reference can tell. The Syncro has the same as a regular vanagon. The shaft comes as either an OG ($100+) or a knock off for 20% of the price.

Sun Jul 20, 2008 8:46 pm

remraf wrote: I'm installing my rebuilt motor tomorrow with new clucth, to bearing, input shaft seal and pilot bearing.

I haven't looked at the cross shaft yet but would like to rebush/replace if necessary. Is it the same as type 2?? Would the bushing kit be the same as type 2? I also have a syncro, shouldn't make a difference?

I don't know if this applys to the syncro. My Bentley is in the garage and I'm too lazy to fetch it. ;)

Beware that the passenger side bushing needs a special puller.

Don't ask me how I know..... and no, I didn't use a puller. ;)

Also beware not to buy the cheap-o type of cross shaft. IIRC, the cheap-o one has a "brass" look to it.

Neil.

Sat Jul 26, 2008 11:32 am

Thanks for everyone's input here. It's very helpful to me to have a community that I can use to bounce ideas against and hopefully learn something in the process.
I spent some time chatting with Daryl at AA transaxle and learned a bunch when I took my transmission over to his shop. The gut is a bottomless pit of Vanagon knowledge! He's working on putting a Zetec conversion from Bostig in his Syncro and adding a turbo to it. It really sounds like a clean set-up. Watching videos on the web of vans with superchargers and turbos is super impressive. I'm starting my penny jar today!!
I've ordered my clutch kit and will pull what appears to be a clutch on its way out this weekend. I'll have the flywheel resurfaced as well. Does anyone know of a good shop in Seattle that can do it? I've heard (read) that this job can get buggered up easily by the less qualified. I'll also check out the condition of the plastic bearings.
Thank you all for your help, support and patience. Hope to see you all on the road real soon.

Mike and the Van called Finally!

Sat Jul 26, 2008 1:03 pm

Andrew A. Libby wrote: Pull the input shaft seal and make sure the oil slinger behind it is a press fit into the bell housing. Replace the seal.

That often ignored bit of my post is very important.

Andrew