[Vwdiesel] Trans. replacement and possible engine rebuild??

[rod welch]

Hello all... Help please...

1987, 1.6TD, Syncro Caravelle.

In 6 weeks we are leaving for a 10000km trip to Barcelona via the Alps... I
need to replace the tranny and, I think, headgasket at least. While I'm in
there I'll consider everything else that could be done depending on your
advice. (bearing in mind, I've never done any major work on a diesel lump
before...)

Last summer I got stuck in third about 300km from home, managed to drive
back and it's sat in the yard ever since. (got my 2wd NA going...) Found a
complete drive train (front, shaft and rear) and now it's time to start
looking at the job. 

First off, I'm not going to connect the drive shaft and change the front box
etc. (got all summer for that job...)
but I need to know difficult it is to check the 3/4 slider? in my
replacement box (I'm a bit paranoid about it now...) and should I replace
all seals and gaskets if I open the case?? There doesn't seem to be any
obvious leaks.

Secondly,  I noticed pressure build up in the coolant system within 15 secs
of start-up and I fear the head gasket is going?? 

What all would you do?? given my situation of minimal budget and maximal
motivation to get an A1 mechanical condition syncro?? (the VC, diff-locks,
de-coupler, tank etc. are already being "processed")

and Thirdly, would it be a lot easier to pull the complete unit and do it
all on the bench?

Opinions please...

rod of finland