My first Beetle :)

crazyguyla · 13 September 2009, 22:09

I'm new here and have an 1970 AS Beetle 1600 DP. I grew up around Beetles and 411's. I bought my sister's Beetle and am glad I finally have one. I have replaced all the vacuum lines and the servo diaphragm (everything had big gaping holes) and everything in the AS system operates like it should (servo pulls the clutch release rod all the way back). I made sure all the adjustments were right before I put the servo back in, but the gears still grind when I try shift it into gear(I think the clutch maybe frozen to the flywheel or the pressure plate since the car was sitting in a field since Katrina said hi to the great south). The car will start in gear since someone previously bypassed the neutral switch (there's a plug where the switch is supposed to be). All three temp sensors and the backup switch are present. I currently have all the seats and carpet out of the car, looking for any elusive rust that could be hiding. The battery floor needs replacing (there's a piece of sheet metal over the hole and the floor kept rusting). There's pinholes here and there in the floor pan that can probably be spot welded. I would paste pictures, but they need resizing(they to big). Last problem is the starter ring gear broke off the torque converter, but I have found a replacement converter(just have get the pennies together)

How can I get the clutch disk free?

Can a AS be push started?

Thanks,

Marcus

Bookwus · 14 September 2009, 01:12

Hiya Marcus,

Welcome to VWAR, our corner of the Volkswagen universe.

Stuck or frozen clutch discs seem to be a pretty popular topic/problem lately. Here's a brief description of how Evan (singlecab61) went about freeing his clutch disc up..............

"I jacked up the back of the car so the rear wheels could spin freely. I bypassed the neutral safety and started the engine with the transmission in 1st (mid range). I revved the engine to around 2500 RPM. With the engine held at 2500 RPM I held the shifter to disengage the clutch and very briefly stomped the brakes. The tranny gave an earshattering bang and the clutch broke loose!!! Yes this was probably bad for the tranny, but it did what I wanted it to do and that was break loose the clutch without having to disassemble the tranny. It worked!!!"

Basically, this is the procedure for freeing the clutch disc. Perhaps Evan will chime in with details.

Good to have you here Marcus. A lot of valuable AutoStick advice and general VW advice can be found on this site.

singlecab61 · 14 September 2009, 06:55

Hello there!

I am sure glad I had this problem a while back. The clutch "unseizing" method I used has sure come in handy lately!!!

You may have to try it more than once in your car due to Katrina. But....If you are puling the engine to replace the torque converter, it would be a smart idea to pull the tranny and inspect the clutch and other mechanicals. It isn't too much harder to yank the tranny and bell housing.

It's up to you.

-Evan

crazyguyla · 19 September 2009, 00:00

Mike & Evan,

Thanks for the help. Once I get the torque converter replaced, I'll post some updates. I have pictures to post, but they're to large.

Marcus

crazyguyla · 26 January 2010, 03:24

I finally got around to replacing my torque converter. The bug runs smooth but still will not shift. I checked to make sure that everything moves when the shifter contacts connect, the servo pulls the clutch arm all the way in. I have adjusted the servo and clutch arm according to volkenstien's direction in this thread
http://www.vwar.org/forum/index.php?topic=19.30. I have tried to free the clutch disk using the early directions, no luck. Is the clutch shaft and clutch arm supposed to be splined or smooth? My electrics are good, the vacuum is good, and all the lines are new 1/2 inch emission hose. Also, the contact points on the shifter were cleaned. Short of pulling out the clutch, what else should i check?

Here are the pics

volkenstein · 26 January 2010, 09:13

Marcus,
Your vacuum connections on your carb are wrong. Someone has stuck a manual carbie on. Have a lookee at my thread somewhere (DIY section IIRC) on how to fix this.

The clutch arm has very fine splines, in fact "faint grooving" is more apt. A gentle scotchbrite up 'n' down on the tranny shaft (faces up for the clutch!) should reveal them.

1/2" emissions hose? Brake booster? The real hi-kwal stuff is available from your friendly (KA-CHING$) Mercedes dealer or go to www.belmetric.com and order 2 metres of RH12W.

There are other methods of attempting to shock the clutch free...but Evan's is probably more practical. You may wind up having to remove the trans. More advice later as social duties call....

You are now on the lunatic fringe of VW ownership

Enjoy
Volkenstein aka Sean

crazyguyla · 27 January 2010, 18:25

Sean,

I looked at your procedure for converting a the carb and it doesn't look that hard

I've been on the lunatic fringe for a long time (own two AMC cars). Having a A/S is more justification. I'm going to pull the tranny this weekend and see what i can sort out.

Thanks,

Marcus

volkenstein · 30 January 2010, 06:22

Marcus,
Hmm..AMC 401cu in...damn fine motor!

If you can keep the TC together with the bellhousing, so much the better. If the TC seal has little use you are probably safe to carefully seperate them.

A big PITA is the lower two Bellhousing to GB nuts..they are inside which means draining the oil (new sump plate gasket thank you!). After that, the Bellhousing has the clutch bits. You will need miniscule socket to get the clutch cover off and some gentle levering *should* work it off the alingnment dowels. Probably best if you mark the carrier plate/clutch cover/clutch disc for re-alignment purposes.

Helps if you have the vacuum servo disconnected and unbolted too...

Look up Dfrommi's GB saga in this forum....

Regards
Sean

crazyguyla · 13 February 2010, 01:12

UPDATE:

Things replaced:

1/2in emmision hose with 12mm reinforced hose(CV to servo)
rubber mounts for cv
heater control cables

Now the clutch disengages and the car shift hard; I am so excited!!!

tomorrow I'm pulling of the carb to drill the required fitting for the CV. Also going to drain and refill the transmission oil (already loosened the fill plug). ATF and engine oil have been changed.

So much work can be accomplished when one is snowed in. Gotta love snow days LOL

Bookwus · 13 February 2010, 04:21

Hiya Marcus,

Quote from: crazyguyla on 13 February 2010, 01:12 .......Now the clutch disengages and the car shift hard

That hard shifting action from a dead stop when shifting into Low or Reverse is a VERY typical symptom of the small vacuum hose from the carburetor (to the control valve) being hooked to the wrong vacuum port as yours is now. You will see a much more moderat shifting action once you have completed drilling the carburetor and switching the small vacuum hose to the correct port. As a matter of fact you may find that you'll need to do some tweaking of the shift adjustment screw atop the control valve.

volkenstein · 14 February 2010, 01:33

Marcus,
2 1/2 threads exposed on the CV adjuster is the factory start point. Get the biggest screwdriver you can fit in the slot.

Enjoy
Sean

singlecab61 · 15 February 2010, 03:43

Hello again,

Great to see you are well on your way to having this bug road happy. One other thing with the small vacuum lines. Volkenstein has already mentioned that your CV shift signal vacuum is connected to the incorrect port on the carburetor and that your carburetor does not yet have to correct port installed.

The distributor vacuum advance line is also connected to the incorrect port on the carburetor. The vacuum advance line needs go to the left side carb port where the CV line was incorrectly connected to. You will need to re-time the engine after you move this line!

crazyguyla · 17 February 2010, 22:25

The AS shifts like a dream now and the wife has absconded the keys (it's her bug).

All that is left is the cosmetics. For an all original 40 yr old bug, that's a lot of cosmetics. I leave for Iraq next month and will have to wait 6 months to a year before I can finish the bug. I thank all of you for your help.

Marcus

Bookwus · 18 February 2010, 00:51

Hiya Marcus,

Our pleasure. We like seeing these cars out on the road where they belong.

Take care of yourself over there! And we'll still be as close as your keyboard, so check in once in a while and let us know how you're doing in Iraq and how your wife is doing with that AutoStick.

Best of luck and thanks for being there.