Essential tasks with gearbox/engine out

[mrbodly]

Hi All

I'm planning on removing the gearbox and engine in my 2L Aircooled to investigate a noisy box. Whilst I'm at it I'm going to repair a leaky pushrod tube as well as repairing and painting the engine tin.

I'm also going to replace the clutch and give the engine a thorough clean, are there any other essential tasks to carry out, such as replacing oil seals etc?

Cheers
Myles

[sarran1955]

Hello,

Change oilite bearing (for starter) in gearbox.

Clean and check good condition/function of heater cables..

Same thing for throttle and clutch cables..

Good time to overhaul the CV joints..

This might help..

https://www.youtube.com/watch?v=meTNBph3rUU" onclick="window.open(this.href);return false;

Also thoroughly clean the two main chassis members that run outside the engine compartment.. good rust trap.

Check the gearbox earth strap..

There... that should keep you busy...

Cordialement,

[300CE]

Change the gearbox fluid, clean up and treat any rust around the engine bay & paint if you wish (I did this when mine was out). Also check, clean and replace any wiring/connectors and wire brush earths to the body!

[mrbodly]

Thank you both for your replies, much appreciated.

Sarran, I enjoyed your video, very informative. I particularly liked the fence post prep!

Engine bay definitely needs treating and repairing, a fair bit of rust to deal with.

What seals are worth replacing? I've noticed a slight oil leak around the driveshaft seal on the gearbox, so will deal with this.

The engine is also using some oil about half a litre every 300 miles. I thoroughly cleaned under the engine, so far I have only spotted a slight leak from a pushrod tube, I assume this wouldn't account for so much consumption. I haven't noticed any smoke so assume it isn't burning it. Any usual suspects on a T25 for oil usage?

Cheers all
Myles

[mrbodly]

As well as dealing with the oil issue I'm going to paint the tinware, is Hammerite ok for this. Would it be able to cope with heat from the engine?

[300CE]

I sprayed up my pushrod tube tinware with Aluminimum High temp paint from Halfords - still looks fine:

http://www.halfords.com/webapp/wcs/stor ... yId_165495" onclick="window.open(this.href);return false;

[sarran1955]

Hello,

As well as dealing with the oil issue I'm going to paint the tinware, is Hammerite ok for this. Would it be able to cope with heat from the engine?

Hammerite is fine..use only Hammerite thinners with..I use wood stove black paint for the hot parts of the exhausts..ordinary metal paint.(or more Hammerite) for the heat exchanger tinware..

As for your oil leak.. it is probably the crankcase oil seal.. especially if you get oil film on the tailgate after a run..

Like this..

https://www.youtube.com/watch?v=aLaA6flr9DA" onclick="window.open(this.href);return false;

Hope this helps..

Cordialement,

[mrbodly]

Thanks for your replies. Another informative and helpful video Sarran, thanks.

[mrbodly]

Hi All

I've removed my engine and gearbox. I split them and discovered the clutch housing is caked in oil, which would explain my clutch judder. I have new seals and clutch to fit.

I'm currently in the process of stripping the tinware and have noticed a lot of thick black gunk, which I assume is oil, around the bottom of the cylinders where they meet the crankcase. Is this likely to be a leak, do I need new gaskets?

Cheers
Myles

[sarran1955]

Hello,

....and have noticed a lot of thick black gunk, which I assume is oil, around the bottom of the cylinders where they meet the crankcase. Is this likely to be a leak, do I need new gaskets?

Clean all this crud off till the engine gleams..

VW Aircooled..Maxim Nr 3....Clean engine = Happy engine...

There are not any gaskets, just paper seals at the bottom of the cylinders..

If you are not touching the cylinder heads then leave well alone..

Look carefully at the pushrod tubes (8)..they will probably be rusty....but hopefully no leaks... these can be renewed without too much hassle..

Clean and shiney.. I want to see pictures

Have fun..

Cordialement,

[mrbodly]

Thanks Sarran

Plenty of photo's to come. Here is the first showing the black gunk. Is this a serious leak or build up of crud over time?

There appears to be several leaks - I'm going to replace

1 pushrod tube and seals (the others look new and don't leak)
Crank seal at flywheel end
Mainshaft seal and flange seals on gearbox
Rocker Cover seals
Dizzy seal
New clutch, pressure plate and release bearing

I've also bought the pushrod tinware from brickwerks so will fit these as well as cleaning and painting the existing tin.
I've also managed to get hold of a couple of new unused thermostats.

I've bought a seal for the pulley end of the crankshaft, it appears fairly grotty in this area. Is it straight forward to replace?

Cheers
Myles

[mrbodly]

Hi All

I've removed the fan housing and found oil caked over everything - please see pics below. Could this be down to the crank pulley seal?

Or is it more likely leaking from between the crankcase halves?

Cheers
Myles

[mrbodly]

Hi all

Just an update to this thread. Engine and gearbox work now done. Back in the van, just need to fit the carbs and setup.
Gearbox rebuilt by Bears Motorsport. Tinware painted with hammered finish hammerite, cylinder tins painted with stove paint. New clutch, various oil seals including crankshaft. New HT leads and dizzy cap/rotor arm.

Repaired salvageable tinware, parts past it were purchased secondhand through this great forum. Pushrod tins, new from brickwerks.

Bought two original unused (correct temp) thermostats from ebay, £45 inc postage!! Fitted new engine bay seal as per wiki - sealsdirect.

Will at last be back on the road next weekend.

Sarran, please see the pics below of my shiny engine. Hope they meet your high standards!!

Cheers
Myles

[sarran1955]

Hello,

To re-use an old advert....

That will do nicely.....

Cordialement..

[mrbodly]

Hi All

The engine is back in the van and running. Despite having replaced the crankshaft seals front and rear, pushrod seals, distributor seal, oil cooler seals and the rocker seals I've identified a couple of new leaks.

The first which leaks a fair bit, when the engine is off, is underneath the sump. Does anyone know what the cover in the photo is for and does it have a seal I can replace? I'm fairly certain this is leaking and it is not leaking down from further up the engine.




I also have slower leak coming from a crankcase bolt at the back of the engine, please see pic. Is the fix for this as simple as sealing the bolt with Blue Hylomar?



I was hoping for a leak free engine having replaced the majority of the seals, so was gutted when I spotted these leaks.
Any help much appreciated.

Cheers
Myles