How To: Vanagon Clutch Replacement 

Glad it helped! nate

Glad we can help! nate

Thanks Matt! How do you like the Bostig? nate

@@ThatBaldwinLife I'm very happy with the power and simplicity of the motor, however we've had some work to do sorting issues with the conversion. I didn't do the conversion so it's been a learning curve for me. Biggest issue has been engine temperature control. We live in Utah so every drive seems to consist of a 3-4,000 foot climb and it runs in the 220-245 degree range often. I added a a Blazecut system and it activated on the first drive and we weren't anywhere close to overheating. I think it just runs hotter than many other setups. I've replaced everything in the coolant system except the radiator, which I was told is new, so you know what is being replaced next! I hope we see you at Syncro Solstice this year!

Thanks Jack! Some of the transmission removal parts are the same! Thanks for watching Nate

🙏🏻 Thank you for the kind words! So glad more people are taking the time to work on their own Vanagons. Nice work! You plan on going to Syncrofest? We are going to try and make it down this year. Nate

Thanks! nate

Glad we could help. Just take your time and assure it all goes back together as you took it apart. Torque to spec and be safe! nate

Awesome! Glad you got it all together Bob, nice work! My puller almost slipped out but did grab at the last second. Good tip on the other attachments. nate

Thanks! Nate

That's a big chunk of change for a clutch. You could have bought the clutch kit, an ATV jack, really nice torque wrench, and the flywheel lock and still had $1500 to left to spend! You can definitely do this! nate

Man I would love to get out to Maine. Well maybe not in the winter! 😄 Nate

I’m in Maine too! Just bought my first westy!

Congrats on the Westy Jack! Sounds like we need to get out to Maine Nate

@@ThatBaldwinLife yes you do!! Check out the Bold Coast!

Wow, what a price jump! Glad the vids help out and we are happy to help give back to the community. Nate

Hoping to get as much info out there so people can keep these vans on the road. Vanagon mechanics are fading out so people will need to learn to work on them. Thanks for watching! Nate

Probably not many have that still and I love that you notice that! Thanks for watching Nate

Thanks, it really is just taking time and doing things step by step. I just like being able to work on my own cars and if something happens on the road, if I have the part (or can get it) I know if can fix it. Gives us some peace of mind driving these old VW’s Nate

You’re welcome! Nate

Funny story as I had a very similar one when I was 14. My dad and I had to swap an engine in an old Datsun and it took us hours to get the splines lined up to mate the engine and transmission. Learned a lot that weekend! nate

Thanks. It wouldn’t be too different. Of course you would have the driveline to deal with as well as the locker actuator to disconnect. Nate

Yeah the rear mounts and driveline would be the biggest differences. Thanks! Nate

Should be pretty straight forward. Good luck! Nate

You bet! nate

You are welcome! Nate

I reused the CV bolts. As long as the heads are not stripped out, they should be fine to reused. Just make sure you have the serrated washers on and torqued properly. Nate

Glad we could help! nate

You’re welcome! Nate

Thanks! Nate

Oh I remember that vividly! Still happens once in a while. This one went pretty easy.

Sounds like it could be the clutch slipping during acceleration. It could also have some oil on the clutch disc causing the slippage so be prepared to fix any leak on the rear main or input shaft on the transmission. No real tips other than what’s in the video. Good torque wrench, locking tool, and Loctite is all you really need. Syncro is the same except you need to remove the drive shaft and the rear mounts are a bit different. Nate

By the way, great video! I hope you make many more.

Yes, 33 ft lbs is right. I just make sure the bolt threads are clean and torque down then recheck torque in a hundred miles or so.

No need to remove the starter. Just disconnect the wiring to it but just be sure to disconnect your battery first. nate

Nate can you provide a link for the flywheel locking tool?@@ThatBaldwinLife

I actually bought it at a local VW shop but they are available online as well. Just search VW flywheel lock tool Nate

Loctite nate

The connection on the transmission is not really adjustable so it can be taken off without adjustment. The adjustment is in the splines where the two shift rods connect. nate

I can have it done in less than three hours if I'm pushing it. Easily in one day. Just have the right tools available. Good jack for the transmission. Torque wrench. Puller for pilot bearing. Correct 8mm triple square bit for CV joint bolts. Sometimes the hardest part is lining the transmission and engine up and getting the input shaft aligned with the clutch splines. Just take your time and don't force it. One thing to pay attention to is when you remove the flywheel to replace the pilot bearing, assure the shims behind the flywheel are not disturbed. There are a few shims and on top (facing you) is the thrust shim. If they fall out/down, place them back in that order and put a little wheel bearing grease on them so they do not fall or move during the flywheel install. Those shims along with the flywheel torque set your crankshaft end play. Very important. nate

@@ThatBaldwinLife thank you! will print the comment you sent me and get ready with the tools.

Yes it is an ATV jack I purchased off of Craigslist. Best transmission jack around! nate

We picked ours up at a local VW parts shop but I’m sure you can get them online. Nate

I picked it up from a local VW parts place. Most online places sell them as well. nate

Eurovans are a totally different animal than the Vanagon. Assume both are automatics? I would have them inspected and get the one with the most maintenance records. Rebuilding a Eurovan transmission is not inexpensive so do your due diligence. nate

Sorry for the late reply, we were on the road for a few weeks! Did you get this sorted? The CV joint should not cause this as it can move in all directions. nate

@@ThatBaldwinLife thanks for the reply. We eventually got it back together but now it won’t stay running. Noticed we split the oil cooler hose during re install of all parts. I ordered a replacement one and it’ll be here soon to see if that’s the issue. Would this cause it to stop running?

The oil cooler will not cause it to not run. Look to see if any sensor or wire was unclipped during the install. Did you plug the AFM back in? nate

@@ThatBaldwinLife is there a better way to communicate? I replaced the oil cooler hose and it didn’t fix it. The AFM is plugged in and I believe working. The van wants to start it’s just not staying running. Love to send you a video to see if you know a solution

You can hit me up at out email address under the About tab on our page. nate

Since my flywheel was relatively new, I just used some brake cleaner and scotchbrite to clean it up. If your flywheel is old or of unknown condition, it is good practice to have it resurfaced. Nate

Thanks for the answer and great content ! :)

Do you have any suggestions for sourcing a good flywheel ? Nice quality and durability

Do you have any suggestions for sourcing a good flywheel ? Nice quality and durability

Do you have any suggestions for sourcing a good flywheel ? Nice quality and durability

Without filming I can have it done in around 3 hours or so. nate

Easier to do with the engine out that’s for sure! Nate

@@ThatBaldwinLife Your trans axle method looked easier. I left the trans axle in place and had to do a complete engine swap, which was a lot of work. I reused the clutch that came with the used engine and it's been holding up for five years. Recent 6400 mile transcontinental trip.

Yeah an engine swap is quite involved. Clutches usually last a long time unless you abuse them like we did. And as you saw, it didn't look that bad. I think the pressure plate was giving up a bit bu the clutch disc was pretty good. But it is a good idea to change them all out at the same time. nate

I don't come cheap