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djkeev
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Joined: September 30, 2007
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Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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 Posted: Sun Oct 07, 2018 12:43 pm Post subject: Re: Getting the 1986 "Westy" back into shape! |
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NOTE: follow this link for complete cover and piston reseal......
https://www.thesamba.com/vw/forum/viewtopic.php?p=8904128#8904128
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Fixing the transmission leak...... FINALLY!!!!!
This is my 4th Fall driving this Van, it has leaked ATF since the first trip!
Sometimes worse than others ....... but always leaking.
I figured out awhile back (2015) that the leak is from the piston cover for the 2nd gear band.
I've sealed the cover externally with magical auromotive sealants but alas...... it still leaks!
I cleaned up the cover and side of the transmission well and it is just sitting cold with engine off. It took but a few minutes for the ATF to leak around my goobered seal job!
To fix the leak you need to drop the oil pan, remove the valve body, loosen the band adjusting nut, compress the piston cover, remove the big clip holding it in place, remove the piston and install new ORings.
Now, I've been absolutely TERRIFIED of this repair and could not wrap my brain around the procedure. I have printed out every article and photo I could find and still it was a mystery to me.
Not wanting tomscrew up the transmission in the car with stupid mistakes, I dragged in the extra transaxle to do one on the bemchnbefore doing it on the car, make my mistakes now where it doesn't matter.
Anyway......
Here is the valve body removed and a clamp on the piston cover to compress it and the piston so that I have clearance and can remove the cover retaining ring,
The clamp doesn't need to be tight, just compress the cover a few millimeters.....
The screw driver tip is pointing to the ends of the big clip holding the cover in place......
The clip comes out really easily! I just slipped a medium size flat blade in the gap and rotated counter clockwise.
Once the clip cleared the transmission housing bore, I used two small screw drivers to "walk" it out......
I found that my deep throated clamp was NOT needed and as a matter of fact was too small for the job, I could not back off far enouth to to allow the piston to come out....... I swapped it out for a 10" C clamp.......
I put a scratch on the cover to key it if needed for reinstallation, but I don't think that it matters......
The cover didn't come out fully...... bummer!
Now, take note of this.... what NOT to do.
I set aside the C clamp and gently tapped the shaft of the piston where it touches the gear band and suddenly "SPRONIG!!!!!!!"
Away went my Cover, piston and spring!
What a mess! Oil shot out like it was propelled by a gun!
LEAVE THE CLAMP ON LOOSELY WHILE YOU GENTLY ENCOURAGE THE PISTON AND COVER TO COME OFF!!!!!!!!
This photo I printed out makes it all look so neat and innocent.......
Truth is that spring packs a Wallop!
Here are the various bits that need to be reinstalled.
You can plainly see why those Orings would leak, they are completely flat on one side!
The Orings are 3mm x 92mm, you need two of them.
I do have concerns about the seals on the piston. I'll run out to my local transmission shop and see if he has those seals. He has been a great help with other items from broken Audi Kits.
He did ask that I NEVER bring him the Vanagon Transmission to work on......
Dave
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Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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| Posted: Fri Oct 26, 2018 4:56 am Post subject: Re: Getting the 1986 "Westy" back into shape! |
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My front brake pads, while not worn out were less than 50% remaining. The rotors were rusty from lack of use but in most cases they clean up well after a few miles of use.
I didn't worry much and clean up the caliper holders and installed new pads.
After a trip to Vermont they were squeaking and decided to pull the wheels and see if things were ok.
I am really glad I did!
It turns out thatbthe rust had badly pitted the rotors and were wearing away the new pads as if a wood rasp were being used on them!
One pad was less than 50% after a quick trip to Vermont!
I purchased some rotors locally from my FLAPS.
It turns out they look really nice and are German rotors.
Zimmermann is the brand with some funky factory applied coating on them, not the typical oiled and wrapped in plastic.
British Brake pads..........
These new ones shoul probide years of service and my old ones clearly demonstrate problems thatbarise because thenunitnis NOT driven frequently!
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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bobbyblack 
Samba Member
Joined: May 21, 2015
Posts: 4353
Location: United States, Iowa
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| Posted: Fri Oct 26, 2018 7:47 am Post subject: Re: Getting the 1986 "Westy" back into shape! |
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Anyone else confused? I thought that thing drove away a few days ago?
_________________
'87 Westy 'Flossie','86 Westy 'R1','86 tintop GL - Subi2.2 'J2','83.5 stock tintop L 'ZoomBus','74 Karmann Ghia, '63 Notch |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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calo1956
Samba Member
Joined: April 18, 2011
Posts: 703
Location: long Island new york
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| Posted: Sat Nov 03, 2018 10:07 am Post subject: Re: Getting the 1986 "Westy" back into shape! |
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Hey Dave, I know you already said good by to your westy, but as i rest today, not feeling well, i started reading your post from 2012! I'm only up to page 11, but i have to say it is awesome, and though i have a air cooled 80, i am picking up a host of info! Of coarse You and so many other members have helped me along the way, but to be able to go back and read your posts from the beginning is awesome, and inspiring! You should write a book! Thanks again!!. BWT i wish i made it ti Flanders this year, maybe next year!
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Enjoy the ride....
72 bug
80 westfalia |
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djkeev
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Location: Reading Pennsylvania
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calo1956
Samba Member
Joined: April 18, 2011
Posts: 703
Location: long Island new york
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| Posted: Sat Nov 03, 2018 12:17 pm Post subject: Re: Getting the 1986 "Westy" back into shape! |
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Will do Dave, by the time i heard about the show, i didn't have time to prepare for the trip. It would be my longest trip to date, and you know, the list of tools was getting ridiculous! Not to mention the camping gear and food, clothing etc, put me over the top!I have to get past that and realize i have a AAA card in my wallet! I do drive my Westy daily, but it is always local to the island, a bridge is a big hurtle for me, unless its the Robert Mosses!
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Enjoy the ride....
72 bug
80 westfalia |
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VicVan
Samba Member
Joined: July 01, 2015
Posts: 1845
Location: Vancouver Island, BC
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| Posted: Fri Oct 29, 2021 8:30 pm Post subject: Re: Getting the 1986 "Westy" back into shape! |
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| djkeev wrote: |
Getting the unit ready to roll I noticed water on the front floor! 
Solution?
A tube of 3M 08509 glass bedding compound.
Easy to install, cleans up well with Naptha.
Dave |
Dave, where did you apply the compound exactly?
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'90 Little Blue Truck, 2WD auto, FAS GenV 2.0 NA (AVH) |
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djkeev
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JEL91Westy
Samba Member
Joined: December 04, 2020
Posts: 211
Location: Central PA
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| Posted: Sun Nov 21, 2021 6:58 am Post subject: Re: Getting the 1986 "Westy" back into shape! |
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Dave,
So would you do anything different when it comes to the process and products you used for the seam rust. My plan was to use a two part panel adhesive after Ospho equivalent. I did the seams in 2011 and am just starting to see staining. At that time I pulled all the sealer, blasted, POR, new two part sealer, and paint. Had the interior out then, but saw very little evidence of rust on the interior of the seams. So as I prepare to do it again, I am trying to get any updated collective wisdom on the process and products.
Thanks for the direct to your thread, good stuff.
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91 Westy
85 911 |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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| Posted: Sun Nov 21, 2021 7:03 am Post subject: Re: Getting the 1986 "Westy" back into shape! |
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| JEL91Westy wrote: |
Dave,
So would you do anything different when it comes to the process and products you used for the seam rust. My plan was to use a two part panel adhesive after Ospho equivalent. I did the seams in 2011 and am just starting to see staining. At that time I pulled all the sealer, blasted, POR, new two part sealer, and paint. Had the interior out then, but saw very little evidence of rust on the interior of the seams. So as I prepare to do it again, I am trying to get any updated collective wisdom on the process and products.
Thanks for the direct to your thread, good stuff. |
The process went well, but to be honest I haven’t seen the Van in several years.
It is still in the family but has been in Oregon with my Brother and about two weeks ago it moved to Tacoma after being gifted to my Niece.
Sadly I cannot make any long term assessments.
I can ask My niece to take a walk around and report back
Dave
_________________
Stop Dead Photo Links how to post photos
Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473
Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537
Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert |
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djkeev
Samba Moderator
Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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DuncanS
Samba Member
Joined: October 17, 2013
Posts: 4583
Location: New Hampshire
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| Posted: Sat Nov 27, 2021 3:11 pm Post subject: Re: Getting the 1986 "Westy" back into shape! |
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| djkeev wrote: |
That was a nice Van.......... heavy Sigh.
Dave |
Yes, it sure is and has the best front heater box of any T3 in existence.
Duncan |
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djkeev
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Joined: September 30, 2007
Posts: 32643
Location: Reading Pennsylvania
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djkeev
Samba Moderator
Joined: September 30, 2007
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Location: Reading Pennsylvania
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