Sometimes I learn things the hard way...DE-COUPLER KABOOM

[Classicvibe]

Like when I didn't tighten the crap out of my axles and they came loose and sheered all 6 bolts on the wheel side...that was pretty awesome.

So on the way home from my weekend trip, I noticed my tranny was starting to make some noise. I couldn't see anything, drove another 50 miles, and now I am seeing some fluid. I get under there and it looks like my brand new decoupler is cracked! I fill it up to limp home and all went well, but I notice it is seriously coming out once I park for a while at home. That was all yesterday.

So tonight, I get it up on the lift, remove the driveline, and the decoupler just about falls into pieces in my hand. It is cracked around 80% of the base?! A little backstory...engaged the decoupler once just to see the light go on and then remembered that I had not hooked that light up so I dis-engaged it. Not that it matters (I hope) because it was never engaged, but my front VC has failed in the open position. I was running some sweet 80-90, and everything was shifting and driving well.

Is there any chance that I did something to cause this? I am totally bent. $60 for Redline gear oil, plus $50 for what I just dumped out from my first install (like 4 months ago), hours of my time and now some bad wear on my transmission. I used GM gasket goop that either Tencent or Terry suggested, and it came out in just a few big pieces. Calling the part provider tomorrow, I just wanted to prepare myself a bit, because as you all know, this part is EXPENSIVE!

I will try to get a pic up, but in the end, it is what I said. Where the curves flatten out at the base where the holes are, the is a crack around most of the piece. Thanks for your input! Crossing my fingers I did not dick this up, I cannot figure how I could have, but that is part of the learning process.

Peace!
_________________
On a mission, the destination is just an excuse.

Syncro Solstice 2022...see you there!

1986.5 Wolfsburg Syncro Westfalia Poptop Weekender Transporter

[blakeck2]

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1986 Vanagon Syncro GL, westy interior, GW 2.4 and all locked up

1973 Thing

[uncommonvw]

If the decoupler is still together and only cracked, could you have it welded instead of buying a new one.

If you can weld it, take your time and only weld a bit at a time so you don't melt the seals or cause any distortion of the housing.

Sorry to hear about your bad experience.

[Alaric.H]

I guy I know Jonathan Seymour had a problem just like that I think he got a new one you could ask him.

[email protected]

[GWTWTLW]

Warranty, maybe? (hopefully!)
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89 Syncro Westy - GW 2.5, now with a double knob job
@gwtwtlw

[pinealservo]

Man, you've been having some terrible van luck lately. Hope you can get a warranty replacement!

[Classicvibe]

The shop was quite nice, and I am returning it today. On one hand I think, these things are all original core parts retrofitted, so anything is possible. But, if there is a way to break something, I can usually find it! Will update with pictures and, the rest of the story, as it unfolds...
_________________
On a mission, the destination is just an excuse.

Syncro Solstice 2022...see you there!

1986.5 Wolfsburg Syncro Westfalia Poptop Weekender Transporter

[Classicvibe]

OK, I got some bad news back from the group from who I bought the decoupler, here is what they had to say:

[Alaric.H]

How hard is it to use a standard nose and put you parts on it?

[Classicvibe]

[syncrodoka]

It sounds like they are telling you that you need the tranny rebuilt or fixed. Spending more money on a decoupler that will fail too is a horrible option.

[AndyBees]

Many moons ago, my uncle "completely" rebuilt an Oldsmobile (could have been a Buick) early model V-6 engine for a guy. The car blonged to the guy's father who had recently passed away... so it was a keep-sake family heirloom so to speak.

Anyway, my uncle told the dude that the engine rebuild would only be as good as the other engine components, i.e., the Carbuerator!

Well, in a matter of months the engine was pretty much shot due to that ole Carbuerator flooding and running rich!

Moral of the story: the weak links will let you down!

It sounds in your case, they did not tell you that other components might need to be replaced/rebuilt. However, they may have also assumed you had that covered!
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'84 Vanagon Tin-top, ALH TDI. 1989 Tin-top
1983 Air-cool, 225k miles, 180k miles mine. Seven trips to Alaska from 1986 thru 2003.

[Alaric.H]

Maybe you should get a second opinion which one do you have the U S or German.Will a standard nose crack because of the same reason I do not hear of that very much I have seen a bad drive shaft rip a nose off.

[HeftySmurf]

Its because your driveshaft was not aligned propperly.
You need to be very tideous on reinstalling it again after adding a decoupler. Also going 80-90 mph with a major vibration will cause a major catastrophy like that.

[tencentlife]

If the pinion shaft front bearings are wallowing out, it would trash any of the decouplers on the market in pretty short order. The nose cover bearing is not designed to carry the heavy sideloading of the pinion shaft, that is the function of the shaft's bearings within the gearbox itself. That sounds like what your tech is describing and what happened to you.

I feel for you but in all fairness, it is entirely reasonable for the makers of an aftermarket component like the decouplers to assume that the person installing it is knowledgeable about the risks of modifying a major component and will perform due diligence before making mods. Transmission shaft bearings are one of the principle wear items on any manual trans, and while the nose cover is off is when the condition of radial play in that bearing could be and should have been checked, since the function and longevity of the decoupler will be so dependent on that shaft running true. It's just not in the purview of an equipment manufacturer to be responsible for every possible problem that could arise in using their product, it is assumed in this case that the mod will be applied to a trans that is in good condition, and it is the clear responsibility, in my opinion, of the installer to know how to assess the application before proceeding.

It would be really swell of the manufacturer to give you the heads up about every potential problem or complication that may arise, but given the numerous possibilities it is clearly not their responsibility. I don't mean to come off as harsh, like I said I'm sorry you're suffering such a big extra expense for what was supposed to be an easy and fun mod, but I'm afraid this one is on you, buddy.

Oh, and as if you hadn't already gathered, your trans is in need of a rebuild.
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Please don't PM here, I will not reply.

Experience is kryptonite to doctrine.

[rowan]

[The Salt]

Ouch... Sorry to hear John. Maybe its time we start the 4x4 Sportsmobile club in SLC. I am dumping a bunch of $ in overpriced power steering stuff right now.
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88 Wolfsburg Edition Weekender

[Classicvibe]

So, tencent...

Good analysis, and I think the burden is indeed on me, but I suspect the manufacturer and seller are considering adding some verbiage to address this in future marketing.

My real dilemma now is that I don't think the pinion shaft is the cause, although I do believe the product was sound, and that I have SOMETHING jacked up on my van.

My reason for not believing it is the pinion shaft is that, I drove for 4 months before I installed the decoupler, and now I am driving again (going on 3 weeks) on my original. Smooth as butter. I have been thinking back about some "vibration zones" at certain speeds that I do not have anymore with my stock cap. If that pinion shaft was dikt enough to trash that decoupler and require a rebuild, this stock would have caved long ago, and there should be all kinds of vibrations, clanking, who knows...but not smooth as butter. I think I cracked the stock seal when I pulled the stock cap off. In other words, that van has 25 years on the stock cap. My brand spanking new decoupler lasted about 5 months. Let me bust out some data and verify dates here:
So, I was driving the van the first week of September 2009.
I installed the decoupler December 19th.
I did NOT install the vacuum lines at this time (like 2 weeks before it dies, but I never engaged the system because my front VC is kissed on the open fail mode.
Decoupler exploded like the second week of May, and I have been driving smooth and happy since.

Here are a couple of shots:

So I am offering this little story as a warning for folks, or at least a heads up on things that might kill your expensive decoupler. My checklist, from easy and most likely, to unlikely pain in the ass, looks something like this:

1) Check u-joints for play on my drive line - Done
I found the smallest play ever, but enough to warrant a fix. I took it to a specialist yesterday and he said its a good idea to repair but this is not likely to have caused the damage. Inexpensive repair that could lead to problems down the road if not addressed.

2) Check drive line for balance issues and repair as necessary. My local shop does not have a jig for that drive line so I need to pull the flanges parts on each end for them to mount and test. I will do this tonight and hand over tomorrow.

3) If no balance issues, remove stock cap and try to get some play out of the pinion shaft. I am becoming an expert on this now. BTW, I never had to lower my tranny. I was able to get the cap off just barely.

4) If no play, check to ensure trans-axles are at appropriate levels. This is probably easy as pie but I don't know how to do it (yet).

5) If I have not found the issue at this point I may be screwed. I guess I will just drive on that stock cap for a while, because I need some solid evidence to go forward with an expensive trannie rebuild. Yes, it is totally likely with the age of this van, but there are no indicators other than the decoupler incident.

6) please insert your idea here. I cannot get a new decoupler until I get this resolved. In the meantime, consider some of the above in regards to your vans decoupler health. That driveline stuff is easy and inexpensive. I think a balance is like $60, and the u joint repair will be less.
_________________
On a mission, the destination is just an excuse.

Syncro Solstice 2022...see you there!

1986.5 Wolfsburg Syncro Westfalia Poptop Weekender Transporter

[syncrosimon]

On my de-coupler I initially omitted the two locating dowels between the coupler and the gearbox. My originals were sent back as the core unit, and the new one did not come with any, nor did I realise that there should be any there.

Just a thought.

Simon.
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1991 16" 2.1 DJ Syncro factory hightop ex Finnish Army Ambulance, now sold.
Thinking about Thing or 181 (182) ownership.

[GFrank]

Just read this thread sorry for your loss.
But great info for those of us installing decouplers.
FWIW this bush looks replacable and the case is definetly weldable by a skilled TIG welder