1970 Karmann Ghia AS project

Sidco7 · 28 November 2009, 07:07

Hello all and many thanks to Mike (Bookwus) and Bjorn (Vwar) for the help in getting registered here.

I have a 1970 Karmann Ghia that is new to us, just bought it this summer. It was an out-of-province car and wasn't insured, but it purred like a kitten on the trailer it was sitting on. Well of course I didn't have time to do a full run-down check or even a compression check on her as it was leaving the province the next Monday. I had to make a decision, and, long story short, bought her, brought her home and found that she shifted really hard, stuck in gear and a host of other minor problems. I know quite a bit about Vdubs as my son and I have a 1964 Transporter Kombi, and he had a 72 Super Beetle up until this summer, but of Autosticks, I know absolutely nothing about. I was actually surprised when the guy told me the KG was auto. After a visit to my local shop guys, we find that #3 cyl is only pushing about 25psi and vacuum is very low. Gonna have to rebuild the engine. At this point, I've spent quite a few hours trying to find information on the net about the Autostick and there's not much out there and so I was on the fence on whether or not to slap a manny into her and pull out the AS. I actually had one lined up for $100. Then I found this place.

I gotta say, there is a wealth of information here on the AS and its all just what I've been looking for in the way of whats what and how to on the tranny side of things. I'm going to rebuild her to original and actually looking forward to the project now. I feel much better that this will be a successful project.

I'll post pictures as I go along. I have the engine out and torn apart already. No. 3 cylinder had a big hole in it and yes, it burned the head out a bit too. Enough to warrent replacement. I havn't cleaned up the block yet to check for cracks, but on first examination, it looks good. Crank and cam look in good shape and so I think I will re-use them. The transmission will be coming out this weekend and then I will spend some quality time 'parts cleaning'. (oh joy)

Anyway, Greetings to all and hope to be able to provide some good "dos" and "don'ts" for everybody to sound on and for everybody else (including me) to learn on.

First up is a pic of the KG and then a couple of pics of the electrical box thats under the rear seat. Can anybody tell me what this is for? I can't find it on any wiring diagrams and I've thought it had something to do with the AS tranny. The big wire is like a spark plug wire and has been cut off. I can't find the opposite end to it and don't know when it might have been cut.

Looking forward to a good forum.
Cheers, Sid

volkenstein · 03 December 2009, 08:43

Mmmm,
More Ghia pRon...love it. Welcome to the lunatic fringe! Looking at a '70 KG wiring diag, I have no clue what that box is for...too many wires for it to be a rear window defogger relay. I reckon you'll be tracing the wires to find out what it is....

Regards
Volkenstein

Bookwus · 03 December 2009, 19:19

Hiya Sid,

Ditto what Sean offered and....................

The only other OEM electrical "box" under the rear seat would be the voltage regulator (at least that's the case in a Bug). So, if it's not the rear window defroster relay or the voltage regulator, it's a mystery box! Yep, pictures would help indeed!

Sidco7 · 05 December 2009, 18:24

Thanks guys. Ya, I've been through the wiring diagrams and through the Bently and still have come up empty. I guess its down to trying to trace the wiring. I'll have to recruit my daughter to help me 'cause thats a two person job. The box really looks OEM, but then, the car is 30 years old. It was originally sold in Edmonton, Alberta and had a few 'extras' like an electric oil heater so that might have something to do with it too. I think it even has a VW part number on it, but can't remember. I'll look when I get back home.

I've haven't got the transmission out yet, ran into problems getting the CV's off. A few of the 12 point hex head socket cap bolts were in soo tight, they stripped out. Finally had to pull out the trusty zip cutter and cut the heads off. After I got the CV's out, I was called out to work and right now I'm away from home, so not much is happening.

I did get to buy a really good ATV jack that will work nicely to lower the tranny out and from under the car. $69 at Princess Auto. Even if I only use it once, its worth it.

Doing all the work outside will slow things down a bit too, temperature is dropping nicely now.

Anyway I'll keep you all posted.

Sidco7 · 07 December 2009, 07:14

A little off the Transmission topic here, but I thought I would share a little trick I learned on pressing out the wrist pins. I use a 6" C-clamp, a small socket and a large socket. The small socket should be about the same diameter as the pin, but smaller than the hole and the large socket should be large enough to allow the pin to escape. It takes a little dexterity to be able to do this by yourself, but with a little patience, it is possible. A third hand is useful though.
On pins that are tough all the way out, I use a deep-socket. This saves on pounding on the cylinders and con-rods.

Cheers, Sid

ASBug · 07 December 2009, 18:05

Quote from: Sidco7 on 28 November 2009, 07:07

First up is a pic of the KG and then a couple of pics of the electrical box thats under the rear seat. Can anybody tell me what this is for? I can't find it on any wiring diagrams and I've thought it had something to do with the AS tranny. The big wire is like a spark plug wire and has been cut off. I can't find the opposite end to it and don't know when it might have been cut.

I am wondering if the Big sparky thing is an ignitor for a Gas Heater. I live in the always green south so I do not know this to be true, but that is the only sparkplug that sits off the engine. Perhaps this is the ignitor for the spark plug that goes with the system?

Just a thought....
KC

Sidco7 · 08 December 2009, 06:27

Well, I've been wondering that myself. There is a gas heater under the trunk that I've not tested. The fan works on it, but there hasn't been any kind of ignition. I don't know too much about them and have had other pressing issues to deal with. What you say makes sense though, and when I get home this weekend, hopefully I will spend a few moments tracing the wiring. If this is true, it makes sense that there is no ignition with the heater because the large wire was cut off. But why would the sparky box be located all the way in the back under the rear seat, when all the business is up front? VW boys confuse the hell out of me sometimes.

volkenstein · 08 December 2009, 10:00

Sid & KC,
I think KC's on a winner! In this great sunburnt (scorched more like it

) country eberspacher's are extremely rare...

Sid, when you have time : http://www.thesamba.com/vw/forum/viewtopic.php?t=314546&highlight=eberspacher

I think this'll be a good guide for you....

Regards
Volkenstein

Sidco7 · 10 December 2009, 20:42

Great thread over at the Samba, thanks for that. Clears up the 'Mystery sparky box thingy'

Now that we have that solved, I will deal with the heater at a different time and place and we'll keep this thread on the topic of the AS transmission rebuild.

Thanks again for the heater thread.

Here is the engine out and I'm home now, so back to the task of pulling the transmission.

Cheers, Sid

Sidco7 · 20 December 2009, 02:11

Well, finally got the transmission out. Some clearance issues with the clutch servo pod and the firewall. Lots of wiggling around and it finally came. Worried about when I go to put it back in will most likely have the same problems.

Has anybody got any tricks on getting the transmission in after it's got a nice coat of paint and stuff without scratching the crap out of the servo?

Now comes the part of the project I don't really care for and thats parts washing and clean-up. Has to be done though, so onward I guess.

Cheers. Sid

Bookwus · 20 December 2009, 06:56

Hiya Sid,

Install the transmission without the servo in place. Once the tranny is in place then install the clutch servo. Yes, it does help to be a contortionist. And welcome to the wonderful world of AutoStickin'.

volkenstein · 21 December 2009, 12:47

Sid,
Buy a packet of icecream sticks! Handy to have along with a piece or two of sharp edged buttery soft aluminium. Prop the trans up on a pair of bricks or whatever so you can clean the muck up as it falls to the ground.

Regards
Sean

Sidco7 · 22 December 2009, 21:37

Quote from: volkenstein on 21 December 2009, 12:47 Buy a packet of icecream sticks!

Good idea.

I also have some good nylon scrapers that I stole from the kitchen

(she wont miss them)

Cheers, Sid

Bookwus · 23 December 2009, 03:37

Hiya Sid,

Quote from: Sidco7 on 22 December 2009, 21:37
......(she wont miss them)......

Enjoy living dangerously, do you?

Sidco7 · 13 January 2010, 06:08

Transmission is out and somewhat pulled apart. I've lined up a shop to do the parts cleaning for me. They have a good sized solvent tank and can do a really good job for me. Hopefully won't be too much, but hey I figure my time is worth something too huh?

The servo is the crimped band style and hopefully doesn't give me too much trouble to get it off. Anybody got any tricks to take it off?

Cheers, Sid

(Ya Bookwus, its the old shoulder shrug and I ain't seen it routine.) The deer in the headlights look helps too...