On 6 Apr 2005 at 18:54, Jim Felder <felder@KNOLOGY.NET> wrote:

I've now done this three times (don't ask... the 4th was with engine and trans
together - much easier!), so I'll add a few things:

> 1. Your biggest concern will be lifting and lowering. I bought a
> transmission jack adapter for my floor jack, but ended up not being
> able to use it because my floor jack couldn't get the back of the van
> up high enough to allow me to use it. It turned out to be no problem,
> though. I placed the transmission on the cup of the floor jack at the
> balance point, and rolled all under the car, steadying the transmission
> with my free hand. Still steadying as I pumped it up to the proper
> height. It helps if your engine can tilt down some toward the front, as
> the diesel does. You may have to think about how to acheive a little
> tilt with the waterboxer, presuming that is what you have. Some people
> have lain on their backs, lifted the transmission to their chest, and
> put it in that way. It could work.

I've done both - the tranny balanced on the jack is tricky, and on your chest is painful
- take your pick!

> Once the front bracket hits the body near where it will mount, it is a
> simple matter to match height and slide the transmission into place. I
> can't think of an easier car I've done that on.

Perhaps the wbx is trickier, but I've always had more trouble on re-installing getting it
to line up and slide together. But then I'm usually more tired by then too.

> 2. The axles will be messy when you drop them. Have some good rags,
> bags and ties. Tie them up out of the way as soon as you can.

Yep, 2 bungies to hook into notches in frame rails, bags and elastics will keep things
clean, both you and the grease...

> 3. The CV joint fasteners must be clean and the wrench tapped home
> before you attempt to loosen them. Easy to mess up.

Yes! This is a big one. Also watch for mixed bolts - I have one allen bolt mixed in with
the 12point bolts that I always forget about... I need to replace that some day.

> 4. Put the engine cover back on when you're not working on the car. I
> didn't, and had to clean out a huge bird nest from the poptop canvas.
> It's springtime, and birds will find their way into a parked van if you
> leave it for even an hour.

I hadn't thought of that one, but I did have a bird in the van a while back - flew in the
garage, then into the open sliding door...

> 5. Drop the shift mechanism at the rear only. Don't do anything that
> will upset the shift adjustment. You'll be sorry if you do.

Yes, just push it to one side.

> Enjoy the repair. It's about the only thing you'll ever do to a vanagon
> where you don't have to bleed the cooling system when you're done.

Also, some padding on your chest might be a good idea :-)

Shawn Wright
http://zuiko.sls.bc.ca/~swright
'85 Jetta D
'88 Westy 2.1L, soon to be 1.6TD 5 speed
'82 Diesel Westy