1986 Canadian Transporter Syncro Double Cab

[ajdenette]

So with lots of Shut downs Due to Covid19 I had 2 weeks off, Unfortunately I chose to store my Westy at my Brother in laws house for the winter and with a shelter in place order and demand for Self quarantine if I go get it I have time to dig deep into the Doka. With some nice days on hand I decided it was time to take the Bus bell housing, the parts transmission, the spare transmission without a bell housing and the Doka transmission and attempt to make 2 usable Vanagon transmissions. The Doka transmission had heavy corrosion on the inside of the bell housing and the clutch arm would not move, but the parts transmission moved easily so the primary goal was to put the good bell housing on the Doka transmission and while I was in there I also re built the locker actuator and got that back in working condition.

Bell housing off and starting to disassemble the differential lock actuator fortunately the piece of hose installed at the factory was still in place and sealed the vacuum actuator well and all of that came apart easily I did have to grind off the through bolts to get it apart.

All of the hardware that was not re usable:

I did eventually disassemble all of these pieces the bracket and sleeve are not reusable in my opinion but the shaft and the spacer were the spacer was re used but a new SS shaft was installed.

Here is the locker actuator going back together with the new parts, I did not find the seals in Van Cafe when I ordered the parts so I went the the hardware store to get standard o-rings, I have since learned where the proper X seal is I do need to decide if I should replace the shaft seal with the proper one or leave the O-ring. I lubricated the O ring when installed and the shaft moves in and out with the actuator using my vacuum pump for brake bleeding and it only takes about 13 to 15 inches of vacuum to actuate it.

I did not want to remove the differential so I was unable to replace the input shaft with my best one but I did clean it up well and put grease in the seal for the bell housing on re assembly.

Here was a funny shot of the parts I was working with, the parts transmission with a bad pinion (heavily pitted) and the three bell housings being utilized.

This is the transmission all put back together and sitting waiting for everything else to be ready to go back together.

I though I was done working on the transmissions, the Doka Transmission on the left, the parts transmission in the middle and the now usable transmission on the floor. Feeling accomplished I headed in for the night cleaned up and climbed in bed. While lying in bed it struck me I forgot the input shaft in spare transmission it was sitting off to the side where I put it out of the way and did not make it back into the box. The next day I put it back on the bench opened it back up and installed the input shaft, it is now set off to the side should I or some one I know need it. I do have another spare transmission that is currently on loan to chojinchef as his trans needed some love but he wanted to keep the van mobile.

_________________
1985 2wd Westy with 2000 Subaru 2.2 current driver
https://www.thesamba.com/vw/forum/viewtopic.php?t=685635
1986 Syncro Doka Project next in line
https://www.thesamba.com/vw/forum/viewtopic.php?t=732777
1990 Vanagon Syncro Base awaiting body work

[ajdenette]

Next up I decided to clean up the gas tank and get it ready to re install, the plug for the gauge sender was broken off and the entire plate was very rusty so time for replacement. upon removal of the sender I found everything inside very rusty so the level sender needed to be replaced along with the split ring I had one broken vent nipple as well. Once the sender was removed I found gasoline varnish that is tar like, to clean everything I found online that Acetone would break up the varnish so I pulled the swirl pot and the in tank filter to clean it up and get better access.

Here is the Sludge that the acetone broke up and came out of the gas tank

Here is everything I used to refresh the tank

Here is the split ring as installed straight out of the package one of my studs snapped and the inside was rusty so I am replacing them. I learned when installing the last set in my 1990 Syncro the studs didn't line up well with the tank or the sender this shows how they overlap a bit so before final install I ground down the ends so they fit right

Using a new sender from Bus depot looks like the VW symbol was removed from the sender

and here is running all of the lines on the top

_________________
1985 2wd Westy with 2000 Subaru 2.2 current driver
https://www.thesamba.com/vw/forum/viewtopic.php?t=685635
1986 Syncro Doka Project next in line
https://www.thesamba.com/vw/forum/viewtopic.php?t=732777
1990 Vanagon Syncro Base awaiting body work

[ajdenette]

I spent a lot of time wiring cleaning up under the dash some one has fixed it all up enough to get it running and driving but there were some things that still needed to be cleaned up. While I was working on all of the under dash wiring and checking things out I added headlight relays and added all the wiring for future a future fog light install with relay fuse and switch installed and wired up and a positive wire waiting to be energized. I had to fix and add much of the radio wiring, there was some installed but much of it in very rough shape and with a lot of it cut out. I had to re built the diff lock wiring as the end wash chopped off after the dash fire and the switch was just tucked up behind the heater duct, I decided to buy the small car interface board as I did not have a connector even though I had a factory board and console. I also added the wiring needed for the map light in GL dash that was installed after the fire.

While I was in there I chose to add the wiring for a seat belt warning light from my parts van and updated the simple brake light that it had before to go along with the US light setup. I don't have any photos but I took the components from one harness and moved them over to the Doka and now have a working door chime relay for the key in the ignition door open and switch in the seat belt warning light as came in US vans.

Also while the Dash was out after trying the wipers I chose to pull the wiper linkage and clean and grease the pivots that freed it up a bit and should make them work better as well.
_________________
1985 2wd Westy with 2000 Subaru 2.2 current driver
https://www.thesamba.com/vw/forum/viewtopic.php?t=685635
1986 Syncro Doka Project next in line
https://www.thesamba.com/vw/forum/viewtopic.php?t=732777
1990 Vanagon Syncro Base awaiting body work

[ajdenette]

With the condition of the Engine that came out of the Doka and even more so the condition of the parts of the engine that came out of the Doka are in rather rough shape lots of rust to try and clean up I opted not to use those parts at this time. I went through all of my spare parts and took a spare Syncro block I picked up a while ago and am preparing to build that up for use in the Doka.

The engine that came out of the Doka:

cleaning up rusty parts first a coat of Cold Galvanizing spray to try and protect the base metal after wire wheeling the rust off, after that dries painting with some fresh Orange paint:

Cleaned the layers of Grease and grime off of these parts the Intake will get painted orange:

New parts and some cleaned parts gathering for building and assembling the engine.

_________________
1985 2wd Westy with 2000 Subaru 2.2 current driver
https://www.thesamba.com/vw/forum/viewtopic.php?t=685635
1986 Syncro Doka Project next in line
https://www.thesamba.com/vw/forum/viewtopic.php?t=732777
1990 Vanagon Syncro Base awaiting body work