Turns out that the real problem was not the clutch itself, but the two
bearings.  The pilot bearing wasn't there anymore; just a bunch of crumbs
and the housing, which took about an hour to remove with hacksaw pieces and
chisel.  The throw out bearing (Sachs) had one of its mounting springs
broken.  The input shaft looks OK, BTW.  The clutch and pressure plate each
have about half - 2/3 of their life left.

I have never completely worn out a clutch in a Vanagon.  It's always been
one of these two bearings wearing out or breaking up, and it's not the first
time that the throw out bearing was still OK, but one of the mounting
springs was shot.

Am I doing something wrong?  Either in driving, maintenance, or assembly?
How can I tell if I need to replace the yoke?  Could this be causing
problems?  The throw out bearing sure looks like a poorly designed part,
with those little springs being all that holds things together.

I tried gently prying on the front (rear?) bearing (the one inside of the
clutch).  Do I need to pry more robustly?  When I removed the flywheel,
there was oil behind the bolts; can I assume that this is evidence of a bad
seal?  Bently mentions an o-ring (always replace).  I didn't see one in
there.  Where does it live?

TIA

Karl Wolz

----- Original Message -----
From: "Stuart MacMillan" <macmillan@HOME.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Friday, January 26, 2001 3:47 PM
Subject: Re: Clutch job

> Any multipurpose grease will do.  Just slide the clutch plate back and
> forth on the splines to get excess grease out of the grooves, wipe it
> off and you will be fine.  It lubes of course, but it's real purpose is
> to prevent any corrosion that would keep the plate from moving freely.
>
> Replace the transmission front seal while your at it too.  $2.00 and 15
> extra minutes is cheap insurance.  I'd also put in a new main seal too,
> just for fun. Have the flywheel surfaced if it has any deep grooves in
> it from the old disk's rivets. If it is smooth just scratch it up
> lightly with some emery cloth to break the glaze.
>
> Karl Wolz wrote:
> >
> > Hello all,
> >
> > I'm preparing to replace the clutch on the '84.  I purchased all the
parts
> > locally (sorry list vendors), and did not get any spline lubricant.
> >
> > My question: what IS spline lube?  Can I use a thin layer of moly
grease, or
> > does it need to be a dry lube, or what?
> >
> > Thank you,
> >
> > Karl Wolz
>
> --
> Stuart MacMillan
> Seattle
>
> '84 Vanagon Westfalia w/2.1
> '65 MGB (Daily driver since 1969)
> '74 MGB GT (Restoring sloooowly)
>
> Assisting on Restoration (and spending OPM):
> '72 MGB GT (Daughter's)
> '64 MGB (Son's)
>
> Stripped and gone but their parts live on:
> '68 MGB, '73 MGB, '67 MGB GT
>