Getting Started

The Rover is pretty well done, so it is time to replace the clutch on my 84 Westfalia van. I had been noticing slippage, especially when pulling my utility trailer.
I am doing this blog primarily to keep a record for myself, but it may be of interest to others as well.

First step.... get it up on jack stands, disconnect the battery and remove the clutch master cylinder brackets.
I ran into my first complication with the upper right transmission mounting bolt. In typical VW fashion, it was very difficult to get a wrench onto it, and it took me a good hour to fiddle it off. The next steps were the two bottom mounting bolts.
The next big complication arose when it came time to disconnect the rear axles from the transmission. The bolts required a 12 point 8 mm driver, a very unusual wrench. I checked around Gibsons, but no luck. Searching on the internet I discovered that Canadian Tire has a little set, but the nearest store with stock was North Vancouver. Fortunately I was going into Vancouver two days later for babysitting our grandson, so was able to pick it up there. Only a two day delay.

Today was the big day of progress, beginning with the removal of the axle bolts on the right, disconnecting the various ground cables and starter wires, then the left side axle bolts. I propped up the engine with an extra jack that I had, and then propped my floor jack under the tranny.
The recommended procedure was to lower the tranny after its forward mounting bolts were removed,  a few inches along with the engine, pivoting downwards at the front end until the tranny was clear enough to shift forwards away from the engine, which stays in the van.
Well, the first hangup was discovering that the top left engine/transmission bolt that I had removed was not the right one! So, a momentary delay as I removed that bolt.
It was then down to struggling to lower the transmission carefully, while pulling forward, to avoid any damage to the shaft that fits into the engine. All went slowly, but well, until I discovered a rubber tube that was hung up between the transmission and the engine. I had no idea what that was because neither my Bentley manual nor the internet page I was following had mentioned this. It turned out the be the tube through which the throttle cable ran, and by the time I figured that out, the throttle cable had severed. Oh well, not too big a deal.
Eventually, the transmission was out and on the floor.

 It will need some cleaning up, and I will likely change the fluid while it is out.
Having a look around after the transmission was out, I noticed that the rear brake hydraulic tubes were rusy, particularly the small on to the right rear wheel. So I will take this opportunity to replace that tube. It was so rusty, it took almost an hour to get the old one off without damaging the union.
I will also consider replacing the right rear axle assembly, as that has not been done in the time I have owned the van.

To be continued.....