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Wed Oct 28, 2009 11:10 am

Anyone have a ball park figure that I should expect to pay for a new clutch to be put in my '77 bus. It sounds like it is a little more then a weekend project for me. I would be interested if people feel this is a good thing for a novice like myself to tackle or if I would be better off paying the $$$ to have it done

Thanks

E

Wed Oct 28, 2009 11:28 am

Shop prices will vary. I don't know a ballpark on that because I have always done my own, even before I was "qualified" to do so, just like you are feeling you might not be qulified.

Cost of parts is about $180 for a complete kit (bearing, plate, disc). I think this is a perfectly acceptable project for a new mechanic, especially if you have a buddy to help push/pull/align stuff. You gotta start somewhere (if you want to). Get the Bentley book, follow the steps, you will be up and running same weekend, no problem. You could do it in one 8-hour day.

Say the word, and you will get a lot of tips on making sure you have the right tools on hand, and some extra tips the book might not cover.

It all has to do with your budget and willingness to learn how to do it yourself.

The only "specialized" tools you might need are a torque wrench, jack and jack stands, clutch alignment tool. All stuff you probably want to have anyway, and you can buy them all with the money you save by not going to a shop... and then some.

Also, while the engine is out, you have the opportunity to fix up some other stuff, but that COULD make your project take a lot longer.

Wed Oct 28, 2009 12:03 pm

Basically the engine has to come out and it is easier to pull the engine/transmission as a single unit.

Been here?

http://www.ratwell.com/technical/EngineRemoval.html

A buddy helps in this process, but you can do it yourself.

Wed Oct 28, 2009 12:04 pm

Here is a good step by step tutorial on the job...You have to decide if you can do it. It has some overkill, like bumper removal, but still a good start.

http://www.ratwell.com/technical/EngineRemoval.html

You don't list your city, but from my experience in Oregon, most larger towns have air cooled VW shops. If you decide to pay for it, find a shop that has a decent air cooled wrench...I would guess about 4-6 hours labor depending on what you do with the flywheel and main seal.

Good Luck.

ETA: Randy beat me by a minute!

Wed Oct 28, 2009 1:09 pm

I'd agree with the 4-6 hours shop estimate and do the math at $70-90 / hour typically shop rate (+ parts).

Wed Oct 28, 2009 2:28 pm

Wed Oct 28, 2009 2:50 pm

thanks everyone for your help. I think I might jump off the cliff and start taking out the engin and see where I go from there

Wed Oct 28, 2009 3:01 pm

Nice!

Don't forget that clutch alignment tool, it's $3 that will save you tons of frustration upon re-install.

Also, the engine-to-tranny bolt by the starter has a D-shaped head. It helps to have a buddy pushing the head down from under the bus while you work on the nut, otherwise it will spin.

I'd suggest a $6 fuel line clamp (a tool, not a hose clamp) from a local parts store, it's skinny enough to get on one of those little soft-rubber fuel hose splices under the bus - avoid a gasoline shower!

Get yourself a little stack of cut wood scraps. I always end up using a few 1-foot lengths of 2.4 and 1x2 for blocking up the engine, jacking it down, etc. Then you can set the engine on those, by the heater boxes, and slide your jack out from under there.

Watch which way you take off the clutch disc. It can get flipped backward, just look at it when you take it off and remember. I think the LONG side goes forward... just take a look to verify. And use that alignment tool!

Any other good tips the book wont give you?

Wed Oct 28, 2009 3:56 pm

Daverham wrote:

Watch which way you take off the clutch disc. It can get flipped backward, just look at it when you take it off and remember. I think the LONG side goes forward... just take a look to verify. And use that alignment tool!

Any other good tips the book wont give you?

I find that I "remember" better if I take a picture of that kind of a thing. But then the 70's were hard on me :wink:

Wed Oct 28, 2009 4:06 pm

Daverham wrote: Don't forget that clutch alignment tool, it's $3 that will save you tons of frustration upon re-install.

It should be in the clutch kit that the OP buys. I've never bought a clutch kit that didn't come with an alignment tool.

Daverham wrote: Watch which way you take off the clutch disc. It can get flipped backward, just look at it when you take it off and remember. I think the LONG side goes forward... just take a look to verify.

You can't install the clutch disc backwards. You wouldn't be able to bolt the pressure plate down if it was facing the wrong way. Good advice to look at how it comes apart and make some mental notes along the way, but putting the disc on backwards really isn't an issue.

Kudos to the OP for diving in and doing this job on his/her own. It seems like a monumental task to pull the engine but in all reality with a Bus it's a cakewalk. The clutch could be done in a day by an amateur but for sure shouldn't take much longer than a weekend.

Wed Oct 28, 2009 5:33 pm

Go for it...

I have pics of the whole process in my gallery. Ignore the one of my son making a lunatic face over the flywheel....

Frank