Skeeter's Vanagon/Zetec Conversion

Thursday, October 19, 2006

Mate the Engine and Tranny

Now you need to mate the engine with the transmission. You're going to hang them both in the bus together. This can be tricky since the two together weigh well over 250kg. That's well over a quarter ton! Watch your toes, eh? I recommend an engine hoist. I borrowed my buddy Jamie's. Thanks, man, I owe you a frosty one. I got the Zetec on the rails and then dragged the tranny over and rested it on a 5X10. Then I got the other end up on another plank. Use the hoist, and body language to get everything to line up. This only took me an hour or so.

Take the converter off the transmission (watch for fluid drips), and mount it to the tranny. Also, it's probably a good idea to check the torque converter bushing and oil seals, etc. If you have an early van you may need to enlarge the hole in the Bostig flywheel a tiny bit. It's just a hair too small. A few passes with a rotary file did the trick. Jim says he'll fix this in the future so it may not be an issue.

The torque converter bolted to the flywheel. You bolt the converter through an access hole in the zetec case. Rotate the crank to bring the bolt holes into view. You can't see the access hole here, but it is pretty obvious.That looks like a lot of engine and a little transmission!

Ready to hoist into the bus. Step two done, have a doughnut. You deserve it.