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Discussion Starter · #661 ·
Put the washer on the correct side and still leaks :(
 

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The original one on my 73 Westy had one seal over the filter and one under the nut like in this diagram:


The one I replaced it with is the same as in your piccy with the plastic filter and only one seal under the nut and it didn't leak.
The one on my bug is the same and no leaks from that either.
 

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Discussion Starter · #664 ·
I saw one pic where there was 2 washers but almost all the kits for sale I have seen have only the one.
Anyway - ordered a metal filter to see if that helps (create a better seal I hope).
 

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Discussion Starter · #667 ·
Weather relented so some work done today - hurrah :)

Replaced the fuel tank nipple with a new one and bought extra washers plus the metal petrol tank filter.
Installed and no leaks so another thing off of the list.

Also bought bolts for the 2 heater cables so I can connect up the heat exchangers and also the bolt for the carburettor.
Fitted and the heater levers now work the flaps in the heat exchangers and pressing the accelerator pedal now allows the engine to be revved (yes, the engine still works ;) )

Step back is the clutch. Pressing the clutch only moved the clutch lever on the side of the gearbox by about 10mm which is not enough to make the clutch do its job :(
It worked fine without the engine fitted so can only assume something is not right and will have to pull the engine I suppose :( :(

No pictures I'm afraid!!
 

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Discussion Starter · #669 ·
One step forward and two back? :(
Well, better than usual as its normally 1 step forward and 3 back ;)
It is what it is I suppose - just not looking forward to getting the engine back out again.
 

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Discussion Starter · #670 ·
11.04.2021

Removed the engine from the gearbox then had to jack up the rear of the van to get it out (wish I had put a removable valance in when I had the chance….)





My jack broke so I had to get another one :(

View of the gearbox - everything looks good in there - thrust bearing and all its bits look fine and move as they should.



A video of the release bearing moving when the clutch pedal is depressed - does it look as it should (looks correct to me)?


Engine in the garage a quick pic of the clutch assembly - thoughts?

 

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Discussion Starter · #672 ·
My thoughts - I took a vid of the clutch pedal end and again, looks good.

(In my favourite vertical format ;) )

 

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Discussion Starter · #674 · (Edited)
I wonder if the clutch cable maybe isn't tight enough and as it new its actually stretching slightly before the clutch arm moves enough?
Can't see anything else that could be wrong.
Not sure - when the weather (and time) permits I will try to put the engine back and perhaps try a lever on the clutch arm to see if can move more?
 

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Discussion Starter · #675 ·
19.04.2021

Grabbed an hour tonight to look at the clutch issue and decided to adjust the bowden tube as looking at pictures and other people commenting that the sag wasn’t enough.
Now looking about right with the sag and the clutch cable is a better fit (not as much spare sticking out!)

A video of the clutch lever movement - looks good.



A video of the clutch release bearing movement which looks to be right too.



Next will be to put everything back and see what happens.
 

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Discussion Starter · #676 ·
Engine back so will finish connecting everything back up and fingers crossed the clutch will work
 

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Discussion Starter · #679 ·
01-05-2021

Today I connected up the electrics and filled up the petrol tank - fired up after some cranking due to fuel starvation ;)

Turned it off and connected the throttle cable, back in the cab and all good. The clutch appears to work now but will know better once it’s on the ground.

Started to add the drive shafts, bloody bearings had fallen out of one so had to disassemble and make it good plus smash a load of grease in - connected and all good.



One problem was I used the washer that came with the bolts for connecting the drive shafts, but it didn’t seem to go far enough down so I couldn’t get the circlip on so used the original washer and all good.



Was going to do the other one, but all bearings were in but one end was far too stiff and at the wrong angle so will pull this one apart and rebuild too.

Also added the foam around the engine tinware - a few pics.







Will try and get the other drive shaft on if the weather holds out and maybe get it lowered on to the drive and test the clutch out!!
 

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Discussion Starter · #680 ·
02.05.2021

Remind me why I am bothering with this van :(

Sorted out the CV joint for the drive shaft so both installed:





Jumped into the cab and started the engine, clutch in and engage first gear - as soon as the gear stick is moved forward the wheels start to turn - so the clutch is still not working. WTF :(

Plus a click noise, probably from that CV joint I sorted so I think I will buy a brand new one to be on the safe side.
But why is the clutch still not engaging :(
 
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