Noob's first post, Fuel pump base stuck inside case....

[donmanolo]

Hello to everyone here, I know it's usually bad form to appear on a forum and ask for help in your first ever post, but please be gentle on me..!

I just brought home my 1974 Yugo-beetle, a 1200J model, built in the volkswagen plant in Sarajevo.( I live in north Italy) and I drove it across north Croatia, and Slovenia before getting home, now I'm fixing up a few minor things while I wait to get an Italian number plate.

Here's the problem I'm having: Basically what happened is that the bottom tip of the fuel pump base has broken off inside the case. The thing must have been 37 years old, as the bakelite is really hard and crumbly.

I just wanted to get any opinions on how to proceed, I've left the thing there for another day while I think about it in Pirsig motorcycle maintenance Gumption trap fashion, (actually my motorcycle is also German, is also an Airhead and is also quirky).

I'm thinking of getting a dremel with a grinding stone attachment and just pulverize the bit left inside, then maybe grind down the new base so at least it'll fit.

Obviously an oil change and filter clean will follow, I'm assuming that this should flush out all the powder.

I'm just worried about what would happen if it doesn't flush out, and if it can cause damage if it finished up where it shouldn't, and maybe somewhere where it could melt while it's there......I'm pretty worried...

I should add that the broken bit is stuck clean inside the case, doesn't even move and is impossible to pry out.

I hope my description is understandable, Thanks for any help and suggestions.

Greetings from Italy,

Manolo

[busdaddy]

Welcome,
I'm not sure grinding is the answer, personally I'd find a large screw or lag bolt to screw into it, once it's screwed in securely I'd start shooting it with carb cleaner to dissolve the varnish that's causing it to bind.
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[JerryMCarter1]

Quote:
Here's the problem I'm having: Basically what happened is that the bottom tip of the fuel pump base has broken off inside the case. The thing must have been 37 years old, as the bakelite is really hard and crumbly.""
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Usually if something drops into the oil case -- nothing happens -- It will finally wash into the oil filter base -- no problem
I am thinking you are talking about a spacer between the case and the base of the fuel pump?

If so your leaking oil ? Correct?
You will have to replace that part

[donmanolo]

Thanks for that, for now I've sprayed it in brake cleaner and left it for tomorrow. I think that I'll tap a thread into it , screw something in then try to extract it that way.

I'm worried because of powder and bits of bakelite that fell into the engine, however I hope that flushing out the oil will get rid of most of the debris.

I'll be back with a whole lot of dumb questions, after I fix this, the brakes are next!

Wishing everyone a great week.

[osborns]

[Mygfsbug]

[Willhelm]

If he actually taps it before screwing a bolt (or stud) into it, expansion is a non-issue. Be sure the hole is correct for the tap size! Good luck!

[Mikedrevguy]

Had the same thing happen to me -
used the tap - and it came out like a charm.
I did take the shop-vac with a 1/4" hose adapter - to vacuum the remnant as thoroughly as possible.
good luck
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[donmanolo]

Just an update.....


Thread tapping resulted in bakelite crumbs falling into the motor, and what's left is totally glued to the part just above the fuel pump cam inside the block.

I don't see any alternative now apart from filing it all down somehow so a new fuel pump flange will fit.

Now I really need to know what bad effects the crumbs might have on the motor, and if they can be flushed out somehow using diesel fuel ...

This is such a stupid thing to happen, and I've no idea what to do...

thanks for any help, and thanks for all the suggestions I received up til now.

Antonio

[Cusser]

I had this happen on mine. I couldn't remove mine with a tap either. I ended up chiseling the old base out, to pieces, with a screwdriver and hammer, then retrieved any plastic pieces out the bottom screen. Did a second oil change after 50 more miles, no issues.
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[NYVWGuy]

My 74 has the same problem. Glad to hear all of these suggestions and that im not the only one this has happened to. Good stuff! I may try this out tomorrow and post the results.

[donmanolo]