These are the situations where the value of a skilled and experienced
mechanic becomes evident. Not only is that bolt tight, it was originally
loc-tited in place. A proper impact wrench will have easily removed it.
Sometimes, heat is still helpful to loosen the thread lock compound.
Taking a hammer to anything on a crankshaft is just not a good idea. The
thrust surface of the case is most likely garbage now. The Bentley shows
the proper tools to restrain the pulley when using a big breaker bar.
Things should never jammed or wedge against the case like that. If the
engine was still installed, using the transmission in gear to hold that
much torque is also risky.

The case halves are machined as a matched set. You can not replace only
one side. Maybe it can be welded and repaired but it probably is not
worth it. Look for another engine.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Mike Williams
Sent: Tuesday, January 31, 2006 2:37 PM
To: vanagon@GERRY.VANAGON.COM
Subject: cracked right side case...i'm in TROUBLE! (was crank pulley
bolt...argh!)

and such is life...my luck with vanagons hasn't yet
changed.  i was working on trying to get the crank
pulley bolt off last night...using my gentle
persuasion methods (a breaker bar with a pipe over the
end of it to give more leverage)...i still couldn't
seem to get the bolt off.  at the moment i gave up
hope, my mothers boyfriend showed up and started
hitting the head of the bolt with a sledge-hammer and
then when that didn't work he took the sledge to the
end of the breaker bar...all the while there was a
wrench jammed in the hole on the pulley to keep it
from moving.

somewhere in the mix...a small chunk of the right side
of the case cracked and fell off (the small piece
which supports the housing for the front crank seal).
i could've cried...but i don't cry...i get pissed.  my
mothers boyfriend is now trying to convince me that
the case can be welded...and i don't know if i should
accept this or not.

so my question(s) is/are...can these block be welded
and still be considered structurally sound...and if
not...does anyone in massachusetts or new england have
a spare right side case hanging out in thier garage.
keep in mind i'm pinching pennies now, because i just
spent a fortune in all the parts for my
rebuild...anyone have any ideas before i find a cliff
and jump?

ugh...i hate to say it...but why is it ALWAYS
difficult...just once i could use some freedom from
failure...

thanks for the help...
mike

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