I have compiled a list of unusually COMMON problems
    that have shown up in our beloved Vanagons.
    I'm not including regular maintenance items
    like brakes, or light bulbs after 100,000 miles.
    These are problems I have seen in a lot of Vanagons
    that are regular premature problem. I am looking
    for suggestions to add to this list. Here is what I
    have so far: 2-25-2002

Common Vanagon Problems------
1 - Water Leaks: front windshield, side seals, side windows
2 - Head Gaskets: need I say more
3 - Water pump: every 50,000 miles
4 - Rear hatch struts: hatch falls
5 - Rear heater: core leaks
6 - Engine idle controls: throtle switch out of adjustment, idle stab
controller unit
                fails, idle stab valve gets gummed up.
7 - fuel leaks: cigar tube, clamps rust, hose brittle
                Plastic fuel fitting on firewall fails
                Fuel tank vent system leaks
8 - Front heater: blow motor seizes,blows fuse, burns switch
9 - Front heater duct/control: internal flap seals deteriorate, air leaks
10 - head light ground wire: wire to small, low voltage, head lights dim
11 - Electrical connections: crimp connectors get hot/melt, several bad
grounds
12 - Power door locks: esp. driver's door, wiring harness breaking, out
of adjustment
13 - Ignition switch: gets intermittent, hot when high beam are on.
14 - Headlight switch: Melts, quits
15 - Inside sliding door handle: not strong enough internally, socket splits
16 - cooling system parts leak: plastic components, distributor on fire
wall, expansion
                  tank cracks, pressure cap. leaks, hose clamps loose
17 - body rust: Seams rust, Cavity in front of tail lights
18 - Clutch pedal linkage: clevis pin wear, play in pedel
19 - Power steering: rack leaks fluid.
20 - Engine performace problem: ECU, wiring to (or) temp. sensor, O2
sensor,
                  constant speed shutter, AFM wearout (bucking).
21 - Non-power side mirrors: mirror will not stay in place, rust in socket
22 - Clutch: chatter
23 - Early slide windows -- glued bearing pieces fall out

    Syncro------
1 - Drive shaft: vibration/balance problem
2 - Transaxle: creeper gear trying to escape, blows hold in case
3 - Transaxle: Synchronizers 3th and 4th break, can not shift
4 - Viscous Coupling: locks up or completely free, hard to detect
5 - fuel sending unit: rusts out, wire breaks off, gauge dead

    Camper------

1 - Fridge: Pilot light blowing out while driving

Cory Sammons wrote:

>I will search the archives as well so don't repeat any long threads.
>Looking at buying a 87 syncro westy for sale in the NE
>Anything in particular I should worry about?
>Known problems / recurring problems etc.
>Thinking of upgrading from my 84
>Anyone want the 84?
>Thanks
>
>Cory Sammons
>84 Westy
>99 New Beetle
>Gardiner, NY
>
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