C

c13tay

New Member
Just out of interest, anyone know what causes the VCU to fail / sieze.

Scoured the web and cant find a dfinative answer - if there is one !!!

Found an american site which seemed to suggest that it may be linked to people batting up ad down the freeway (as they call it) at 80mph treating the freelander as a sports car and not a 4x4 - they seemed to think that this overheats the gloopy stuff inside the VCU and this makes it loose some of its viscous properties

Might be a load of poop but thats what they think.

Any other ideas ??
 
found this - not specific to freelanders but ..............



Interview with a Viscous Coupling Expert


by Derek Drew
I located this morning an expert who works at a manufacturer of viscous couplings. As part of a lengthy interview, he said these things:
viscous-coupler.gif
    1. The viscous coupling fluid goes bad over time when it acquires small metal particles from the surrounding metal and suspends these particles.
    2. The process of having the fluid go bad is called "gellation" and was caused as a reaction causes a gas to be formed.
    3. You can fix a VC by replacing the fluid with fresh fluid. You should also examine the condition of the plates.
    4. The percentage of air in the viscous couling is critical, and the percentage is almost always a low of 80% and a high of 86%. He said that if you went above an 86% fill then you would have the VC activating on the highway during normal driving and a dangerous situation would exist. If you went below 80%, he said you might never achieve lockup, even when stuck. He said all these numbers are subject to investigation and confirmation, which he will try to give me in August after consulting with Europe to check on our exact unit. He said the probable range for our vehicles is 84% to 86% air -- possibly closer to 86% for a vehicle intended to go off road as ours is.
    5. He said a room temperature VC should *not* be under any internal pressure, and that it might be a simple fix to partly repair a VC to simply open up the bleeder holes and let the fluid under pressure in there out and then put the plugs back in and keep using the unit.
    6. He said that he wanted to help us in order to keep VCs from getting a bad rap amoung OEM manufacturers. He said that even if his company did not make the SDP units themselves, his company would have an interest in helping us and making sure our VCs were not wearing out prematurely and that they were being rebuilt properly.
    7. He said that if Wheedle and Oregon Transaxle were refilling the VCs without letting any air get into them (which both Wheedle and Oregon told me!!!) then the rebuilds from Wheedle and Oregon would be faulty. The symptoms would be early wear, intense heating of the VCs, and lots of premature lockup.
    8. I observed that this might be the reason Wheedle and Oregon both told me they are moving to a lighter formula fluid--that they are mistakenly not adding the required 14% air and that they are not rebuilding the units correctly. The GKN official agreed that this is a logical possibility. He said the idea of a VC being 100% filled with fluid was something that would simply never be done under any circumstances. This statement tracks the statements of the engineer Wolfgang in Tim Smith's article from VW in 1979.
    9. I believe it is possible that after my guy checks with SDP that someone will shut him up and they won't talk to us any more.
    10. He said the proper refilling procedure is to apply pressure at one little hole while applying a vacume at the other little hole .
    11. He said the key to preventing the fluid going bad over time was additives in the fluid that his company routinely uses. He said it is possible that SDP does not use these additives.
    12. He said the fluid gets hot and that this is what causes the lockup.
    13. I asked him why the VC doesn't appear to have any air in it and asked him why it seemed to be 100% fluid. I asked if perhaps this was a special VC that required 100% fluid. He said that no, this would not be the case. He said that in manufacturing the air is added and then the air gets mixed up in the fluid and occupies the little holes between the plates of the VC and you cannot see the air any more.
    14. He said not to quote him on any of this. I guess that means I should leave his name out. :) I think what he really meant was that he wanted to investigate and confirm what he told me.
Conclusions

    1. Anyone with a bad VC should hault any work being done by Wheedle and/or Oregon until we resolve the issue of the % air.
    2. Anyone with a bad VC might want to simply vent it, reseal it, and reuse it, and see if that fixes the problem.
    3. Derek gets this week's "VC Award."
Additional Info

Derek Drew offers this additional information from a 'the very best sources':
​
    1. If you refill a VC so that it is full it will burst its seals. Never refill so it is full. (The proper percent air is 84% to 86% according to an estimate from another expert familiar with Viscous Couplings but this percent cannot be confirmed yet.)
    2. The plates inside the Viscous Couplings have microscopic burrs on them that are critical to the proper torque transfer of these units. This means that the plates wear out and cannot be reused!
    3. Since replacement plates are not available, this means Viscous Couplings should not be rebuilt until a source of replacement plates can be identified.
    4. Any viscous coupling under pressure is likely a bad viscous coupling! If you open the unit, and a lot of VC juice comes out, the VC is likely bad.
    5. Viscous Couplings have a useful life of 60,000 to 90,000 miles. After that, they are worn out and should be replaced. This makes it sound like they should be replaced as often as your clutch!
    6. There is no difference between the Viscous Coupling fluid in the 14" and 16" models.
info@vanagon.com
Copyright © 1997-2006, Ron Lussier. All rights reserved.
​
 
superb article. Sheds new light onto the VCU. Maybe that is another reason for moving to an electro-magnetic type of clutch rather than the viscous coupling type?
 
Nice one ctay!

can you ask him how much his juicey stuff costs and where you can get some from ?
 
you dont hang about Mondo !!!

was going to have a look at mine later.

Suppose there must be some kind of plug or how do they get the fluid in when they make em ??
 
c13tay said:
you dont hang about Mondo !!!

was going to have a look at mine later.

Suppose there must be some kind of plug or how do they get the fluid in when they make em ??
Click to expand...

dunt bother mate its ferkin freezin out there :eek:
i'll post sum piccies

hang on !;)
 
LOOK !

NO plug oles !
 

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That fust pic dunt look too good tho !

I seem to have a bit of a damp patch

i think the plugs (if there are any ) must be inbetween the two drums
wonder wot appens when yer take the three bolts out ?
 
so then after 60k miles its on its way un 90k yer bin lucky. . .un no point in re fillin it ta 80% cos the plates are shot soo its a new one. . .wot is the stuff inside called? is it silicone or a mixture ,shurly hydrolic oil would do the same job, oh un wot rpm does it take up drive un has it got a time slip. . . .
 
Hat Man

Thats a shame - it says its a sealed unit. having said that it must be dismantleable (is that a word ?) cant see it being sealed as in welded - surely the heat from the weld would have some detrimental effect on the jelly.

Im sure ive seen someone selling a VCU refurb kit for the freelander on flea bay

Have to see if I can find it again - see what you get and what you do.
 
Refurb kit is only for damper on VCU on flea bay. Expensive at that! Looks like VW Westfalia synchro (vanagon in US - where's my vanagon????) used same VCU manufactured by Steyr Daimler Puch. On SDP website it even states they manufacture for freelander from 1997 Steyr Daimler Puch All Wheel Drives

Also on VCTest is the same VW tests us guys are going through. I saw on VW forum a reference to a company called Fast Forward who claim (ed) to have a unit to replace VCU but I cannot find more details although they could be Canadian??? Maybe someone knows more?

Seems Mondo mode is popular with Wesfalia VCU failures as well. Nice to know we are not alone. I think Mondo is on the right track with his research as it seems VW guys have also gone through the pain of all of this and also haven't had much success with a solution. Definately a non serviceable item for us DIY and also a need to be wary of buying recons by the look of it.
Keep up the good work MONDO - Smiles
 
yup i agree wif smiles we now know that ya can exspect 40k miles -90k if ya lucky , un if on flea bay they start to re-fill um, if the plates are shot its a waste of time, the problem wif the mag clutch/brake system is gonna be a=cost or b=gettin it to fit, as far as wiring logic this should be easy to overcome on this site, we are still lookin. . . .:)
 
Ive just mailed the bloke from the Vanagon site to see if they have made any progress

will post his response when and if I get one.
 
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