Swapping gearboxes: how to? ['81 DIESEL]

[AndyBees]

Jeffery Lee, that's my jack in the Harbor Freight link.... only difference, mine come from Northern Tool... and seems I paid $200.00 about 12 years ago!
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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.

[?Waldo?]

I got an actual transmission jack a few years ago after the first time I wrestled an automatic trans out of and into a Mk4 Jetta. I got the Harbor Freight 'cheap' one and it is similar in cost to the previously linked ATV jack. https://www.harborfreight.com/automotive-motorcycl...60234.html The distinct advantage to a transmission jack is that it has the two handles that adjust the angle of the saddle on the jack. After having R+R'd several transmission with it I'm a big fan. Overall the trans jack is a more flexible tool to use than the ATV jack (which I also have). Neither a trans jack nor ATV jack is specifically necessary for a Vanagon trans install which is a comparatively easy trans install. I've done several of them with just a $20 FLAPS trolly jack although the cheaper methods tend to involve more risk/stress/effort in the doing. Regardless of what type of jack you use, a large part of the challenge is that the engine must be angled down in order for the nose of the trans to clear the frame, the trans has to be inline with the engine, AND the trans needs to be moved toward the engine along that same centerline of crankshaft and transmission input shaft. When you consider what you want to use to do the lifting, bear in mind that it will need to move toward the back of the van while at the same time lifting the trans in order to maintain that proper angle.

[epowell]

[Jake de Villiers]

[epowell]

Here are some pics and some more questions...

I heard that when re-installing the clutch pressure plate it is necessary to have a special alignment tool to keep the clutch aligned... is it possible to use this spare piece to make such a tool? This is from the DK I think, and my pigs are all DMs.

Here are the 2 dead pigs I want to test out.

In these 2 pics is it possible to locate and checkout the "oil slinger"?

Here is a 3rd dead pig which has a known bad 1st gear, and missing bellhousing.

I also have a whole box full of DK innards (minus RP) [sorry that box is BELOW the box in this pic]

Here is my whole stash including a JX block I want to rebuild next Winter

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www.edwardpowell.com

[AndyBees]

The splines may be the same, but the end will not fit the pilot bearing in the end of the Crankshaft. To make the alignment properly, the guide pilot must fit into the pilot bearing...

Edit: Nope ... after taking a second look, splines are not the same. Also, that reverse shaft is basically identical in both the diesel and DK trannies...
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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.

[epowell]

Cheap DIY tranny jack! Wow, this looks like the best and cheapest I've seen.
I would make it much lower though.... just very small wheels attached to a thick slab of plywood and bolt the Z-jack onto that. But wow, this one holds the tranny solidly and is very moveable and flexible also > looks ideal.

Link

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www.edwardpowell.com

[MarkWard]

Take your worst looking transaxle and pull the bellhousing off. It will give you the chance to look at the condition of the ring and pinion. At the same time, you can remove the input shaft and use it as a clutch alignment tool going forward. 30 mins work.
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[epowell]

[Zeitgeist 13]

[epowell]

[epowell]

[?Waldo?]

I've just eyeballed the alignment of several clutch discs and had no issues. It's a little easier to use the alignment tool or input shaft but not strictly necessary. A good eye gets it just as well aligned as the tool.

That single scissor jack on a little furniture dolly like that would likely not stand up to a vanagon trans.

[epowell]

[epowell]

this probably is the most simple and easy that I've seen...

Link

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www.edwardpowell.com

[MarkWard]

The bellhousing is the one case member you can safely install using sealer in place of a gasket. In fact, it will probably seal better with sealer than a gasket.
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[epowell]

[MarkWard]

Don't get carried away with the sealer. Just a film not a gob. Machined surfaces could get away with no sealer. Not sure if you can get it there, but Loctite makes a product called Gasket Eliminator. It's anaerobic and works well for sealing machined surfaces.
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[epowell]

[MarkWard]

That sleeve is what the release bearing or throw out bearing rides on. The release bearing is a wear item and usually gets replaced with the pressure plate. It is moved against the pressure plate fingers to release the clutch disc so the input shaft slows for a smooth shift. Spin the center with your finger it should feel smooth and quiet, not notchy and noisy. You will need to transfer that tube and replace the input shaft seal under it.
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