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Sun Jun 08, 2025 8:44 am

Hi all this is my first time posting something here, but I need a little assistance, currently undergoing my first rebuilt for my 1968 Volkswagen Beetle and got the engine case back after having it machine and dipped for the engine has gone 20 plus years give or take without a good proper service, but when we got it back there is a gear stuck in the case that being the gear for the distributor we have tried soaking it in oil and everything yet nothing, is it supposed to be like this or what do I need to do to get it unstuck this is the only thing preventing me from finishing my rebuild so any info on this matter would be great. Here is photo of the gear that I am talking about thanks.

Sun Jun 08, 2025 9:10 am

Does it turn?

Sun Jun 08, 2025 9:18 am

they sell a special tool to pull these , but i think upside down it should fall out :-)

the tool is typically trying to lift it out in upright position , like with motor still in car .

the tool goes in the slot , you tighten it and it expands / bites the part so it can be lifted out , there a washer or two there as well .

id try a large screwdriver in the slot n see if you can get it to spin , i dont think anything is holding it .

Sun Jun 08, 2025 9:30 am

It looks like the fuel pump rod bakelite support is broken off in the case.
That may prevent the distributor drive from coming out of the case.

Is the drive stuck and not moving, or it moves but you cannot get it out of the case?

Sun Jun 08, 2025 11:51 am

That’s the distributor drive gear, and it looks like the upper half is missing - ? Broken off, maybe??

I’ve never seen one of those broken/sheared off like that before, and so am thinking it might have gotten jammed or seized up at some point. If so, could be stuck pretty tight in the case, and require some serious coaxing to get it turning again, and eventually totally out. I’d inspect the case for other damage as well - might have been a catastrophic event in another location that contributed to breaking that gear, who knows?

Sun Jun 08, 2025 12:09 pm

67rustavenger wrote: It looks like the fuel pump rod bakelite support is broken off in the case.
That may prevent the distributor drive from coming out of the case.

This is what it looks like to me as well.

However, in 2016 I took apart my factory 1971 engine (its first time to be apart) and I also could not extract its distributor drive gear, and I have the correct tool and there was no fuel pump spacer in the way. I ended up using a block of wood and a hammer to tap that out.

0, and I also could not remove its distributor

Sun Jun 08, 2025 12:49 pm

Brody Mason wrote: Hi all this is my first time posting something here, but I need a little assistance, currently undergoing my first rebuilt for my 1968 Volkswagen Beetle and got the engine case back after having it machine and dipped for the engine has gone 20 plus years give or take without a good proper service, but when we got it back there is a gear stuck in the case that being the gear for the distributor we have tried soaking it in oil and everything yet nothing, is it supposed to be like this or what do I need to do to get it unstuck this is the only thing preventing me from finishing my rebuild so any info on this matter would be great. Here is photo of the gear that I am talking about thanks.
Looks like it is fubar'd. Question one why did your machinist not point this out and two why would you not point it out to them?

Sun Jun 08, 2025 1:16 pm

i see what your talking about now , looks like 1/2 a drive gear and part of the bakelite spacer !!!

Sun Jun 08, 2025 3:57 pm

Well to answer the question on why we didn't notice this is because the case was tightly sealed we couldn't get it open for of the gunk on it, I'm the cars third owner and it has been kind if neglected cause a lot of the parts are still original from factory and 20 plus years takes it toll when you don't properly take care of the engine. Now then so if the thing is messed up should I get a new one?

Sun Jun 08, 2025 4:12 pm

Quote: Now then so if the thing is messed up should I get a new one?
No, it's stuck in the case.
There's no need to replace the case just because the distributor drive is stuck in place.
Break that plastic fuel pump rod guide away and remove the drive.
The pump guide is bakelite a kind of old durable plastic that been around for over a century. It gets brittle over time and heat cycles.

The guide is available at most any VW vendor for cheap.

Sun Jun 08, 2025 4:14 pm

doesn't look good to me , ya got get em out to see if its salvageable . to be jammed up i imagine some case metal is distorted / damaged , should be easy enough to get the spacer piece out maybe then you get at the gear better .

like how did this happen ? something hit the distributor that hard is all i can think of .

Sun Jun 08, 2025 4:24 pm

Sorry should have clarified should I replace the distributor drive gear not the actual case after spending so much to get the case cleaned I Don't want to lose it sorry about that. Also no Idea with what happened I've only owned the car for 6 years and previously mentioned I am the cars third owner we bought it off someone. The engine was in rough shape when we first got it and it ran but it needed some serious attention because of how it was feeling and running when driving hence the current rebuild.

Sun Jun 08, 2025 4:46 pm

this is what one looks like , i dont see the upper half of yours .

Sun Jun 08, 2025 4:56 pm

my3bugs wrote: this is what one looks like , i dont see the upper half of yours .

I believe the rest of it is there I just think that broken plastic piece is covering it still is it just a safe bet the get a new drive shaft gear so I know that this thing doesn't come back to haunt me down the line

Sun Jun 08, 2025 5:03 pm

Break out the plastic piece, then remove the distributor drive gear and clean it and the recess well. If it turns OK, re-use it, that's what I did in 2016. That VW was still running as of mid-day today !!!

Sun Jun 08, 2025 5:08 pm

the harder i look i can now see it may all be there but its behind the fuel pump spacer . get that spacer out it it may just let go ?? the spacer still looks to be aiming the rod in the right direction .

what are you waiting for ??? it doesnt look as bad i had first thought . its prolly ok ??? let us know ???

Sun Jun 08, 2025 5:28 pm

Will do I am getting with my buddy who is helping me rebuild the engine as its at his place later this week to tackle it I will post how everything goes thanks for the all the advice everyone really helps me out with this.

Fri Jun 13, 2025 9:13 am

So update, we got the gear out thanks to all the advice you lot gave me, the gear unfortunately is no good the teeth are all jacked up so I ordered a new one, but thanks to everyone to helped now I am on the path to getting the engine restored and driving my Beetle again.

Fri Jun 13, 2025 9:22 am

How many shims under the gear did you see? Show us a close up of just the gear can we see where it’s worn?