Another Autostick problem

dfrommi · 05 July 2007, 15:59

heres a side shot of the servo http://s4.photobucket.com/albums/y150/danfrommi/karmann%20ghia/?action=view&current=IMAG0056.jpg

the bolt head is actually a bolt and nut to replace the pin and cotter pin and original bushes for now. when trying to get the arm off originally with out taking out the engine not even beating it with a hammer could get the pin out of the plastic bushings so i melted them out. i just replaced it for now with some plastic bushing from the local hardware store and a nut and a bolt. i took and tapped the threads with something pointy on the bottom of the nut and bolt to lock it in place so it can be slightly loose with out coming undone.

volkenstein · 06 July 2007, 05:12

dfrommi,
Looking pretty good from that angle. If that's where it sits "at rest" and your measurements check out, then I'd reckon you are good to go.

Is that shot before or after you'd printed my post and adjusted it all again?

Not knowing what your schedule is, mine is hectic the couple of days so you may not get speedy answers out of me....I'll squeeze in some time to look at Klaus and the Spare's servo/arm positions..

Regards
Volkenstein

dfrommi · 06 July 2007, 19:33

it was after i printed the instructions out. right after getting the trans it i thought it was going to rain but hailed! with almost like tornado speed like winds. it had my maple tree in our back yard side ways and busted out a few screens in our windows. glad it wasn't too big of hail. http://i4.photobucket.com/albums/y150/danfrommi/07/IMAG0064.jpg?t=1183743008
http://i4.photobucket.com/albums/y150/danfrommi/07/IMAG0060.jpg?t=1183743150

volkenstein · 08 July 2007, 06:10

dfrommi,

In this first shot, the servo arm is retracted, the splined clutch shaft has been rotated clockwise and then the clutch arm slipped just on, and rotated to 35mm centre to centre between the servo arm eyelet and clutch arm. I pushed the clutch arm onto the shaft all the way.

So pull out comes the servo arm, put the bushings into the clutch arm then slipped the servo eyelet in there and dropped the pin in and here's a shot along the bellhousing/trans joint.

Interestingly (for me anyway!) the scribed marks I made on the clutch arm/shaft aligned perfectly. You can just see it in the second photo.

For you, given this clutch has seen 102,000 miles, the first photo is what you want to set everything to. Where it sits after it's all joined up will be OK regardless.

Hail....damn...isn't it summer over there? What the hell, we've had snow in November here..

HTH
Volkenstein

dfrommi · 14 July 2007, 00:10

yeah its almost mid summer. but thats Michigan for you. all seasons in one day. got the engine and trans in and now to put all the electrical where it goes. I've got all the electrical for underneath the car done and the generator. I'm not very good with these wiring diagrams but it will work out okay I'm sure. quick question whats that little box right under the ignition coil with 5 connectors on it?

volkenstein · 14 July 2007, 01:33

dfrommi,
Can't help there as I've never seen a KG's wiring outside of a Bentley. Could be anything.
Cobey?
Paging Cobey!!
Nova?
Any other KG owners?

Volkenstein

dfrommi · 22 July 2007, 01:27

yes!! success! got it started long enough to test it out and it shifted into 1! so it turns out that it was 1: a bad bladder in the servo 2: the clutch arm was skipping teeth on the clutch shaft

68autobug · 22 July 2007, 05:27

the splines are very fine on the clutch shaft...
so the bolt does all the work...
I always put a bolt right thru and a nut on the other side...
probably overkill....

Sean,
My two spare servos don't have the screw on the chromed strap...
the strap is crimped over both sides and doesn't come off...
I've sprayed a lot of armorall into them- both sides...
neither leak...

My clutch pressure plate has 8/89 stamped on it... Sachs..
and one of the servos has 1986 stamped on it..
so they have been replaced at some time...

Lee

http://community.webshots.com/user/vw68autobug

volkenstein · 22 July 2007, 06:10

Dfrommi,
Winners are grinners!! Good news indeed, and don't forget you can tailor the shift speed to as fast/slow as you want with the screw on top of the CV.

Lee,

QuoteMy two spare servos don't have the screw on the chromed strap...
the strap is crimped over both sides and doesn't come off...

Eh???.....VW or someone else got stingy!!!

They both work so not a problem..'89 & 86...wow..all my stuff needs carbon dating

Regards
Sean

Bookwus · 22 July 2007, 09:17

Hiya df,

OUTSTANDING! Major obstacle hurdled! The rest of the problems will look like minor bumps after this. You are on your way toward becoming the AutoStick expert for the Great Lakes region!

dfrommi · 22 July 2007, 19:21

i took it for a test drive today

man i really love this thing! i just wish i fit in it better

i cant put it in low gear with out my legs knocking it out of gear lol and my foot kinda hits the brake and gas at the same time. after a few adjustments on the control valve it was shifting awesome. just wondering are you suposed to let go of the gas in between shifts? and at what points is it good to shift? the rpms didnt really seem to change much at all.i think i maybe got it up to around 40 mph just going down my street. have to wait to get the plates and tags to drive it legally on the city streets heres of a movie of her first flight. http://s4.photobucket.com/albums/y150/danfrommi/?action=view&current=fa894cce.flv
sorry for the helicopter noise i don't know whats wrong with the camera i guess its just getting old

Bookwus · 23 July 2007, 04:19

Hiya df,

Wooo-Hooo! There is no better feeling than rolling out "the project" for the first time.

A couple of driving tips.................

Yes, let up on the gas when you shift. You'll get the hang of that in short order.
Be sure to keep your hand off the shift lever knob when you are not shifting.
You can use the shift point indicators (the little red marks) on your speedometer for maximum shift points. The shift point indicators are keyed into the manual transmission (so disregard the shift point at 11 mph) but the rest work just fine.

68autobug · 23 July 2007, 11:27

Hi,
Don't forget you can use all the 3 forward gears...
the VW manuals used to state that Low gear was only to be used when parking
going up steep driveways etc..
but I find it good to accelerate out on the highway or from traffic lights...
its better [I find] to use Drive 1 or drive 2 when parking...
as you can really take off when using Low gear...

Your gearlever should only disengage the clutch if its pushed forwards or backwards..
Not sideways....
I have purposely knocked the gearlever with My knee to see if it would go out of gear,
and it never has...
I thought that front seat passengers may be a problem with the gear lever,
but I have had No problems...

I just remembered...
My Left knee hits the gearlever... as we have Right Hand Drive cars
and drive on the Left side of the road...

Maybe the lockout plate under the gearlever stops the gear lever from disengaging the clutch when You bump it on the Right Hand Side..
so, knocking it [on the LHS] with Your Right knee may work
differently ??

Lee

http://community.webshots.com/user/vw68autobug

dfrommi · 24 July 2007, 06:01

quick question: is the control valve supposed to be that noisy when you switch gears?

68autobug · 24 July 2007, 07:07

I don't think I've ever heard the control valve make a noise...
its just an electromagnetic solenoid which switches the vacuum
to the Clutch servo on/off..
If You are hearing a THUMP
that is the clutch servo making the noise...

Mine used to be very bad,
but now its acceptable...

Lee

http://community.webshots.com/user/vw68autobug