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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Tue Apr 29, 2025 7:12 am Post subject: Checking Endplay |
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I have a motor that I want to rebuild. The PO said it was built to a 1641. I started to take it apart, Then I thought I should check the endplay. From the fly wheel, I tried to move it back and forth. It wouldn't budge. One way or the other. looking into it further, took the fly wheel off and found that there were only two shims behind the crank and the were both .001 of an inch, to a total of 2 thousands. Are there supposed to be 3 shims? With end result being from 3 to 4 thousands to be an acceptable range? If its to tight, could that be a problem? It turns ok when I turn on the pully clock wise. To those in the know, Why is the endplay so tight? Thanks all
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halfassleatherworks Samba Member

Joined: December 09, 2018 Posts: 770 Location: Reno NV
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Posted: Tue Apr 29, 2025 8:16 am Post subject: Re: Checking Endplay |
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Put the flywheel back on and take a reading. then make up a shim pack with three shims, your reading minus .004 for pack total. if your gage is reading right you have .023 thou, 23 thou not 2. thou is the 3 digit. . tenth, hundredth, thousandth, |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Tue Apr 29, 2025 8:40 am Post subject: Re: Checking Endplay |
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Thank you halfassleatherworks will take heath. But isn't it supposed move, even a few thousands?....If its too tight, could that be a problem?... Perhaps a bearing issue, or the crank?....... |
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halfassleatherworks Samba Member

Joined: December 09, 2018 Posts: 770 Location: Reno NV
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Posted: Tue Apr 29, 2025 8:48 am Post subject: Re: Checking Endplay |
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your 2 shims at .023 are to thick, as I said remove all shims put the flywheel on and check, if you don't have any play with shims out you have a problem. |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Tue Apr 29, 2025 9:18 am Post subject: Re: Checking Endplay |
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halfassleatherworks.. I'll check, but I believe this might an issue. So if that is the case, what kind of problems will I run into? |
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oprn Samba Member

Joined: November 13, 2016 Posts: 14574 Location: Western Canada
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Posted: Tue Apr 29, 2025 2:37 pm Post subject: Re: Checking Endplay |
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The number of shims is immaterial (one shim, five shims)as long as the end play is correct when you are done. A combination of three shims just happens to work out in most cases due to the thicknesses they come in. _________________ Our cars get old, we get old but driving an old VW never gets old! |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Wed Apr 30, 2025 7:06 am Post subject: Re: Checking Endplay |
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W ill post on my findings, a soon as I'm able. Thank you all for your responses....  |
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tpinthepack Samba Member

Joined: July 11, 2004 Posts: 845 Location: clearwater,florida
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Posted: Thu May 01, 2025 4:06 am Post subject: Re: Checking Endplay |
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I was taught years ago to install 2 shims at first without the flywheel seal, take the measurement, then use math to determine the size of the 3rd shim needed. I have a good supply of shims on hand and never have an issue getting this correct. I agree 1 or 2 does not matter, but the method that I use makes is very simple. I use a magnetic dial indicator, and a standard micrometer on the shim not the Vernier caliper, but it should be fine.
Good luck. _________________ TP in the Pack (I am a cyclist)
1968 Manx N.O.S. w/ Barrett Chassis
1960 Single Cab 1914 w/ 40 DLRA's
1990 Vanagon DOKA
1972 Super Beetle
1979 Super Beetle Convertible
2011 Porsche Cayenne |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Thu May 01, 2025 5:18 am Post subject: Re: Checking Endplay |
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tpinthepack... Thanks. Its taking a bit to get in the garage to work on my engine . I 've read on some of the forums, and they insist you need the three shims. once again I will post my findings, and hope all this information will help others as well... |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Thu May 01, 2025 1:15 pm Post subject: Re: Checking Endplay |
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Having a hard time posting pictures. I set the dial indicator to where I thought it should be. Up against the fly wheel. No shims. Moving the fly wheel back and forth with assist of two large screw drivers, gently moving them of course. It just barely moved perhaps 0.001 either way... I might be doing something wrong as to where I positioned the dial indicator. Don't know .Do I need to add shims?.... Please advise,and thanks... |
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Dale M. Samba Member

Joined: April 12, 2006 Posts: 20771 Location: Just a tiny bit west of Yosemite Valley
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Posted: Thu May 01, 2025 4:00 pm Post subject: Re: Checking Endplay |
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legotech7 wrote: |
Having a hard time posting pictures. I set the dial indicator to where I thought it should be. Up against the fly wheel. No shims. Moving the fly wheel back and forth with assist of two large screw drivers, gently moving them of course. It just barely moved perhaps 0.001 either way... I might be doing something wrong as to where I positioned the dial indicator. Don't know .Do I need to add shims?.... Please advise,and thanks... |
For dial indicator the body mount is generally placed/mounted to engine block.... The anvil (probe) of dial indicator is usually resting against the clutch surface of flywheel.... Push the flywheel hard into block, record reading on dial, pull flywheel hard outward from case record the reading, subtract smaller number from larger number the answer or product is number of thousands of free play..
Maybe not best or perfect video, but does show the procedure....(and Its not mine)...
https://www.youtube.com/watch?v=hMpRmgR3LkM _________________ โFear The Government That Wants To Take Your Guns"
"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ... |
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oprn Samba Member

Joined: November 13, 2016 Posts: 14574 Location: Western Canada
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Posted: Fri May 02, 2025 2:29 am Post subject: Re: Checking Endplay |
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legotech7 wrote: |
I've read on some of the forums, and they insist you need the three shims. |
It's like the story about the newlyweds cooking a turkey for the first time and the young bride cuts a big slice off the top of bird and throws it in the garbage. He thinks it a waste and asks why.
"That's the way Mother does it"
He phones Mother-in-law and askes her.
"My mother does it that way too"
When he asks Grandma she says "I do that because my turkey pan is too small to put a lid on."
Old habits die hard. If I were to build the "perfect" engine for my air cooled VW I would chuck the crankshaft up in my lathe and trim the butt end until it had the correct end play with zero shims. That's less parts to wear out and fail.
I have rebuilt a number of other V8, V6 and 4 cylinder engines and NONE of them have required shims to set the end play. It is also not a common thing to find excessive end play in any of those engines as they rack up the miles like our air cooled engines do. So... is it a which came first, the chicken or the egg with our end play problem? Do we use shims because there is a problem or is there a problem because we use shims? _________________ Our cars get old, we get old but driving an old VW never gets old! |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Fri May 02, 2025 6:00 am Post subject: Re: Checking Endplay |
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Thanks Dale for the video. Sometimes I have to sit back clear my mind and finally things come into perspective. I moved the dial up against the body of the case. Then it all fell into place. 0.030 minus 4 = correct? Now to get some more shims. I understand they are had to come by.. More searching!!!!!! |
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Dale M. Samba Member

Joined: April 12, 2006 Posts: 20771 Location: Just a tiny bit west of Yosemite Valley
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Posted: Fri May 02, 2025 6:46 am Post subject: Re: Checking Endplay |
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legotech7 wrote: |
Thanks Dale for the video. Sometimes I have to sit back clear my mind and finally things come into perspective. I moved the dial up against the body of the case. Then it all fell into place. 0.030 minus 4 = correct? Now to get some more shims. I understand they are had to come by.. More searching!!!!!! |
Not really.... Any good VW site the has engine parts should have them....
https://www2.cip1.com/search-results-page?q=flywheel%20shims _________________ โFear The Government That Wants To Take Your Guns"
"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ... |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Fri May 02, 2025 6:48 am Post subject: Re: Checking Endplay |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Fri May 02, 2025 4:56 pm Post subject: Re: Checking Endplay |
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OK... Got done with the endplay. Quite an experience...Love this stuff...Anyway, this engine has these heads with the scat rocker arms. I don't know what size valves are in them. The PO said that the engine was built to 1641. Might the heads still be stock, but they only added the rocker arms, and will that hurt anything in the mostly stock engine? They did say that it had some chatter from the right side head. Perhaps they are loose?. I haven't delt into them yet, thought I'd get some more opinions from the group...Again thanks in advance...
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EVfun  Samba Member

Joined: April 01, 2012 Posts: 6072 Location: Seattle
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Posted: Sat May 03, 2025 4:28 pm Post subject: Re: Checking Endplay |
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I keep seeing this image and a thought keeps going through my head.
1. I think I see an o-ring seal in end of the engine.
2. I think I'm seeing a metal gasket in the front of the image.
Does this engine have an older crank and flywheel and need the metal gasket to seal, or does this engine have the newer o-ring seal? The end of the crank and flywheel are different between the two. _________________
Wildthings wrote: |
As a general rule, cheap parts are the most expensive parts you can buy. |
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Dale M. Samba Member

Joined: April 12, 2006 Posts: 20771 Location: Just a tiny bit west of Yosemite Valley
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Posted: Sat May 03, 2025 6:20 pm Post subject: Re: Checking Endplay |
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Actually in very first pic there is a "O" ring in flywheel.... _________________ โFear The Government That Wants To Take Your Guns"
"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ... |
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legotech7 Samba Member
Joined: May 09, 2009 Posts: 973 Location: North Carolina
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Posted: Sun May 04, 2025 4:21 am Post subject: Re: Checking Endplay |
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In the pictures where you see the seal , was only placed there so I wouldn't loose it. It is not pressed in all the way and the metal gasket placed to the side. The other pic,I was trying to measure the shims. I managed to set the end play within its tolerances after making sure I set up my dial indicator correctly, with the help of many of you here. Three shims set at 4 thousands of an inch. Torques at 260 lbs , using a torque multiplier...Don't know if I trust that aparatus....But I hope it good .......
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Abscate  Samba Member
Joined: October 05, 2014 Posts: 23616 Location: NYC/Upstate/ROW
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Posted: Sun May 04, 2025 10:53 am Post subject: Re: Checking Endplay |
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Correcting above. Three shims is important, not just the end play. You need oil and three shims to control the wear of the flywheel against the case boss. _________________ ๐บ๐ธ ๐บ๐ธ ๐บ๐ธ ๐บ๐ธ ๐บ๐ธ ๐บ๐ธ ๐บ๐ธ ๐ ๐ ๐ |
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