Syncro Modifications
How does this thing go back together again?
Leaky Problem
A few months after I bought my van in 2003, I noticed some suspicious coolant staining around the heads. This was likely the infamous "vanagon head gasket syndrom". I didn't want to run the risk of my van exploding somewhere out in the sticks so I decided to install a rebuilt motor. I picked up my motor from The Bus Depot where they sourced it from AVP, a California engine rebuilder. I found them very helpful and, so far, it's been a dependable motor. WAIT, NOT SO FAST.... I HAD A PROBLEM
Old engine out of the van and seperated from the transmission
The shiney new engine
Transmission
While I was at it, I also opted to replace my transmission since the old one kept popping out of first gear on deceleration. Again, since the motor was out, this was easy enough to do. Luckily, I found one of the few sources for syncro transmissions is a 3 hour drive from Portland in Bend, Oregon (central Oregon). Also as luck would have it, it appears that these same people were also the source for my front locking differential. I bought the van with this already installed so I didn't know where it came from; I was happy to hear that it was from a reliable shop.
New transmission
Drive Line Decoupler
One optional thing I did decide to do was have a drive line decoupler installed on the new transmission so the van could be switched from 2-wheel drive to AWD during bad weather or for gravel roads.
Drive line decoupler. Blue/black servo on the right is what engages the drive line
The decoupler has been a great addition to the van. With the addtional MPG I am now receiving (about 18 mpg as opposed to the 16 mpg the full time syncros get) I figured it would pay for itself after about 60,000 miles. I'm sure this figure will be much sooner now that gas prices have gone skyward.
Putting it All Together
New engine and trans ready for installation
The complete assembly went together pretty easily. When doing this I took LOTS of pictures before I started ripping things apart. This was just so I could have a reference in case something was confusing. I also labeled all wiring junctions so I could easily hook them back together. This made things a snap.
Drive Line Treatment
Drive line installed
Since I had the drive line out of the van I decided to paint the pitted surface. I found that using oil based Rustoleum brush on paint provided an EXCELLENT seal. Even after 30,000+ miles the shaft can be hosed off and it looks good as new. It also matches the mount flange for the drive line decoupler, thus giving it a more consistent look.
Final Thoughts...
I'm no mechanic by trade, and yet I found this to be a relatively straight forward task. Having a good selection of tools (Decent tools at cheap prices) and a modest amount of space to work in, the average back yard mechanic should have no problem swapping out a vanagon motor in a week or two, working on it only "part time". BTW, yes, it helps to have friends that are gear heads that can loan you parts you wouldn't normally buy like cherry pickers, transmission jacks, pullers, etc.
Doing the engine/trans swap was not cheap especially after you add in the drive line decoupler - about $6,000 total. But it's much cheaper than the estimates I had called around on - anywhere from 10 grand to mid-teens. In the end I'm glad I did the work and it's extremely nice to know that the van shouldn't leave me high and dry when I need it most.
Problem in '07
Mid year, '07 update - So much for totally reliability! The #3 cylinder sucked a valve so I ended up having to have the head rebuilt. While I was at it, I opted for the super-duper refined head upgrade with stronger valves. Should (hoping) last many thousands of miles to come where the original head gave me around 40k miles. Oh well, fingers are crossed!
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