Conrad,

I once looked at the different clutch discs while at the location of
VanAgain.com.  The more expensive definitely is thicker and more
substantial.  But the cheaper one works just fine and last for lots of
miles for people.  I made the decision for my old 84 based on projected
time and distance of use.  I knew that Van had a limited life expectancy
with me due to all of its problems so I went with the cheaper one and it
was still working fine when the van was stripped last fall.

If I thought I was going to keep a particular van for at least 50k
miles, I would put in the heavy duty clutch.

I found that the clutch in my Syncro which is supposed to be the HD (I
didn't buy it) is easier to push down than the stock one that was in my
84 and the replacement.  The clutch in my 85 is more like the Syncro.  I
don't think one needs tree trunk legs to push any of them.  From my
experience, the HD has to do with the build of clutch plate, not the
effort required to push the pedal.

Regarding the $80 difference, many think it is.  Most of the cost of a
clutch job is $$ for labor or your time for labor.  If the HD clutch
lasts 30% longer, it is probably worth it if you intend to keep the van
for a long time.

Usually, not always, the failure of the master or slave is gradual and
you notice some softness in the pedal for a few days before it gets to
the point where it won't work.  So if the pedal starts having to be
pushed closer to the floor to disengage the clutch and engages closer to
the floor, fluid is leaking somewhere and you had better check the
master and the slave and the brakes also.  I have always gotten some
warning (about 5-6 slave failures in 20 years), but ignored it /
procrastinated a day or two a few times and twice came out to find the
van's clutch inoperable the next morning.   Now I pay quick attention to
the soft clutch pedal.  (Or hope I will have learned my lesson.)

--
Sam Walters
Baltimore, MD

89 Syncro GL
85 Westy Weekender

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