Removing a Vanagon Syncro Transmission....Basic Tips

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START HERE : ...this document does not attempt to be 'every tiny screw & wire' step by step....it's more of a basic overview and description of how to proceed.
CAUTION !!! Do not attempt this unless you are pretty darn good at car repair...this is like level 8 on a scale of 10 as car repair goes...big heavy parts, big vehicle up in the air etc.....Use this completely at your own risk ! This particular job is NOT for your ordinary back yard mechanic. ( see cautions at end, below )

( NOTE THIS ! : Very often the way people learn about fixing something on a car properly involves ruining what they are working on the first time they attempt it ! Be careful ! )

OK THEN :

Before anything, get the rear skid bars/skid plate out of there completely, of course. Disconnect battery of course. Remove the air filter assembly....this is obvious and general FOM ( facilitate other maintenance...an aircraft maintenance term ..there may be other minor things like this. )

Then Either,
A. Pull the engine and transmission as a unit, then separate them out of the syncro. ( this is well worth considering... It's a considerably 'cleaner' way to do it. I don't think there is a time penalty either, actually. )

( no need to ever touch the fuel tank, btw...unless you see rusted/rotted fuel tank straps and want to fix/replace those, or do other fuel tank-related repairs )

OR
B. Pull the trans only. BUT THERE IS A trick for that :

Lower the engine down enough to remove the starter, by undoing the bolts at the outer ends of the Rear Engine Carrier Bar....at the 'frame raisl.' Battery was previously disconnected, of course.
Then put the engine back up ...hang it back up by the engine carrier bar... Exhaust can stay untouched...watch the O2 sensor wire, that it doesn't get stretched. Remove O2 sensor if need be. ( nice to know it's not stuck in there anyway. Put anti-seize compound on the threads of it going back in. )

Then remove the driveshaft . Undo the inner ends of the Axles at the inner CV joints. Remove wires and vent line from the transmission. Unbolt the clutch slave cylinder from it's bracket....( don't open the hydraulics ) ..and secure it off to the side. Make sure you get all the 'little things' attached to the transmission undone. ( there's nothing like wrestling with a giant heavy part like a transmission only to find you forgot to undo some minor wire or hose or something....damage is often the result of overlooking little things like that ..so be careful there ! )

Then, just remove the trans from the engine. ( support engine from falling, of course ! ..duh )

Be careful at all times not to pull too hard on wires, coolant hoses, throttle cable ( might want to undo that too ..or at least consider it ) ... Using this method the trans will come out with most of the engine stuff still connected. With care you don't even have to open the cooling system ( though, given how much coolant there is in a syncro, and how it doesn't all come out easily, and how much corrosion goes on in old coolant...it's ALWAYS good to change some of it out. You almost can't change it too much, even. )

To go back together, reverse the process.

What you will find.....or what usually happens....
Since these beasts are so hard to work on in this area anyway....for major things like a clutch or transmission rebuild.... 'while there' you'll see other things 'that would be nice to do now' ... Like a clutch slave cylinder... Or those rusted-to-hell fuel tank holder straps ..etc. Projects have a way of growing like that.... Like if the starter is 12 years old...'well...sure is a lot easier to deal with now' ...it can go on and on like that sometimes.

FINITO .. ...and....BE CAREFUL working on cars ! There are THOUSANDS of ways to hurt yourself or to do damage to what you are working on !!! ....Just to be clear about that ....Very often the way people learn how to fix something on a car properly involves ruining what they are working on the first time they attempt it ! .....About personal safety .....vehicle falling on you, heavy things falling on you, STARTING A FIRE, cuts, smashed fingers...all possible. The learning curve on car repair is very steep at first....like YEARS. Just do good work, enjoy it ( proper tools....boy do they help ! ) and enjoy the results of your efforts. Scott