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  View original topic: Syncro locker vacuum hose routing
Dirtyhippy Fri Feb 12, 2016 12:19 pm

I am trouble shooting my locker. Everything seems to be solid, junctions aren't loose, hoses aren't cracked, actuator moves if I blow into it. Just don't seem to be getting a vacuum. Where does the vacuum source start at the intake manifold? I have followed the lines into the engine bay only to see them tuck inside a hole above and behind the engine into the chassis. Where do they go from there?
On another note, is there a canned smoke to make this easier next time?
[img]https://www.thesamba.com/vw/gallery/pix/1464401.jpg[/imv


I presume that this is the breather for the differential?

ScottShelley Fri Feb 12, 2016 12:25 pm

Look under the van on the driver side. There is a 3 bulb canister that is the vacuum reservoir. There is a large vacuum line going to the brake booster that is Td to feed the reservoir. You should be able to check the vacuum there to start.

insyncro Fri Feb 12, 2016 12:54 pm

Verify vacuum at intake.
Make sure check valve is operating properly.
The locker system is very simple.
The stock lines of this system are colored, white, blue, black.
Make sure that you do not have obstructions or broken lines / connectors.
The stock rubber L connectors develop cracks at the bends.
The actuator can also be tested if disconnected at the shift coming out of the trans.
A roll pin holds it in place.

I have documented many of these parts, shown tricks and proper 3 knob routing in the Corter thread.

http://www.thesamba.com/vw/forum/viewtopic.php?t=525134&highlight=corter

Yes it is a long thread, but filled with Syncro specific info.

Hope this helps.

ScottShelley Fri Feb 12, 2016 2:43 pm

This might be helpful also.
http://www.thesamba.com/vw/forum/viewtopic.php?t=319128

Dirtyhippy Sat Feb 13, 2016 4:08 pm

I hooked up a mighty vac to everything and tested. It all seemed to hold. Then checked the hg at the manifold line, it went to 15 hg, then hooked it all back up again, then it started to work. I'm wondering if I dislodged something when I applied manual vacuum to the system. However, the actuating pin moves only about halfway. I'm not moving the wheels( while underneath) so, is it possible we just arent lined up and engaging all the way yet? No
Light on the dash yet either.

ScottShelley Sat Feb 13, 2016 4:27 pm

To get the locker to engage you will need to have the two rear wheels spinning at different speeds. I usually test by doing slow s turns on an unpaved road.

Dirtyhippy Sat Feb 13, 2016 4:40 pm

Testing tomorrow. I will post a new update, pictures, et cetera.

Dirtyhippy Sun Feb 14, 2016 1:51 pm

I drove the Van around for 15 minutes on a gravel road, swerving, turning , a lot...... Pin drives only about halfway into the cylinder. Could it be that the po replaced things and the roll pin was pushed through a little too far, scored the cylinder? [/img]

Dirtyhippy Sun Feb 14, 2016 7:31 pm

Got the punches out and gently tapped the roll pin into the diff lock pin.
Wasn't happy with the result so I tapped a little more and dragged my leather man outbound the outside edge hoping to dislodge any burrs. Cleaned it up with a magnet and a towel. Took it for a test drive.
We have light!!!! So I climbed underneath for another looksy....
Too dark to go mudding. I will have to try it again tomorrow....

insyncro Mon Feb 15, 2016 1:53 am

Awesome :!:
Enjoy the locker, it is a God sent when in the thick of it.

Syncro Jael Mon Feb 15, 2016 6:18 am

I put a short piece of clear tubing over the actuator and pin. It has a small hole to let you access the roll pin with a punch. I also use the hole to squirt Fluid Film inside the tubing to keep everything lubricated. The clear hose is nice to keep everything clean and you can still watch the movement. Just FYI.



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