Thanks Dick.  Excellent suggestion, especially considering that the problem
occurred both before and after the slave cylinder was replaced.  I'll
definitely have them check this when they get back to work on Monday.

-Wes

From: sailingfc @dslextreme.com [mailto:sailingfc@dslextreme.com]
Sent: Saturday, May 02, 2015 8:56 AM
To: Wes Neuenschwander
Cc: vanagon@GERRY.VANAGON.COM
Subject: Re: 91 Westy - Mysterious Clutch/Transmission Problem

Even though you replaced the clutch master, did anyone check the clevis to
clutch pedal connection?  If the hole and clevis pin are badly worn, you may
not be getting full clutch disengagement.

Good luck!

-Dick-

On May 2, 2015 08:21, "Wes Neuenschwander" <wes.neuenschwander@comcast.net>
wrote:

I have a '91 Westy with a fairly new/rebuilt engine (Go Westy) and
transmission, now with about 40,000 miles on the combo.  The last few years
I've pretty much 'archived' the vehicle, keeping it in the garage except for
occasional road trips.  I took it into my local VW 'go-to' shop in Seattle
(Fine Tuning Performance - absolutely outstanding service on the vehicle for
the last 20 or so years!) for routine service (oil change, coolant flush and
change, replace brake and clutch fluid) and during the post-service test
drive owner/head guru Chris noticed difficulty in engaging the van in
reverse.

He thought the problem was most likely a failure in the clutch hydraulics
that was preventing the clutch from completely disengaging (and since
reverse has no syncro, the 'grinding' noise would only occur in reverse).
They replaced the clutch slave cylinder (the master was replaced a couple of
years previously), but the problem persisted.  Next step was a clutch job,
including replacing the idler bearing.  Unfortunately, it's still grinding
when engaging reverse.  Huge bummer, especially as we were planning on
heading out for a fishing/camping trip to a remote area in NE Washington
next week!

If anyone has *any* ideas what could be causing this - persistent, and now
mystifying - problem, you suggestions would be *much* appreciated!!

-Wes