Rescuing a 1979 Transporter

[RONIN10]

Tackled cleaning the headliner tonight just to get the muck out and make work on it a bit more enjoyable. This is only Round 1, but a big difference nonetheless. Here's some before and afters...

Front:

Side:

Rear:

Some overall finished pictures:

Round 2 will occur at a later, unspecified date.
_________________
Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[RONIN10]

The last few weeks have been busy with buying a new bus, selling Greta, and travelling for work so not much has been done with the '79. Now that things have settled a bit and with Amskeptic's visit a little over a week away, I need to get cracking!

Tonight, I managed to repair the mouse-chewed portion of the engine harness where it pigtails to the AFM. The damage wasn't too bad actually, only one wire chewed through completely, another wire only partially through the metal, and two more with only the insulation gone through.

So I soldered and shrink wrapped in splices and zip tied a corrugated wire sheath around the whole thing. It's not going to win a beauty contest, but should be functional and durable.

A few weeks back, I ordered a fuel hose kit from German Supply. I inquired about shift Steering couplers since I had seen that this bus's wasn't looking too great when I took off the steering tube to get at the ignition switch. Turns out they had 2 NOS ones in stock. I got both, one for this bus and the other disk for my other bus. So this is the task for tomorrow night, change out the fuel lines and pray that there's no rust in the tank. I'm not hopeful, but new goodies are always fun!

After that, all that's left to do is add gas, change the oil, and get a new battery and I should be ready for Amskeptic to come on the 16th. Hopefully, we can actually get it running then. Looking forward to it!

Tcash
_________________
Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[EZ Gruv]

Those stripes are fantastic.
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Eric
1977 Deluxe Westfalia - 2.0L FI Type IV, Completely Original
Photographer for HotVWs, VolksWorld, AirMighty, VW Camper & Commercial, Hayburner, and more.
My Photography Page.

[RONIN10]

Fuel hose kit installed:

...also completed an oil change. The only things left to do before Amskeptic's visit is to get fuel, buy a battery, and fabricate a temporary battery tray out of plywood. With all those boxes ticked, we should have all the major obstacles to getting the bus running addressed. Cross your fingers for a blissful report at the end of next weekend.

There is still a nasty stink of mouse piss in the engine compartment as well as general mildewy smell in the cabin. So other than getting it running, heavy cleaning is the next big priority.
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Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[Wasted youth]

Excellent write up! Fun little extraction episode

Your fuel pump has an winning chance of ruining your day. I say this from personal experience...

It has been sitting far too long with old gasoline inside of it, which has by now likely turned to thick varnish. If you are patient and careful, you can actually take that pump apart from its can, and thoroughly clean it and reinstall it. If you choose to do that, be highly attentive to how it comes out of the can and put it back together right.

Or you can just buy a new one for less than $100.

But all of that work will be for naught if you don't also clean out the gas tank and add a pre-filter ahead of the pump if you cannot yet clean the tank.

And... as previously noted, totally cool striping! Nice potential with that bus~

[RONIN10]

[Wasted youth]

Okay, cool. The sediment in your tank may be sloshed and re-agitated when you start driving, but right now your gas comes out clean. Just be aware of this potential.

I suggested a pre-filter for your fuel pump because of the unknown condition of the fuel tank. No need to clog the fuel pump!

So, yes two filters for now: the pre-filter (any decent filter that will fit up) to protect the pump until you can renovate the gas tank, and the filter guarding your fuel injection system. Two filters; one temporary and one by design.

[RONIN10]

Last Saturday (16 July) was my IAC day with Amskeptic (Colin) this year. I spent the last few days before he arrived getting as much ready as I could so that we’d have the best chance of getting the 79 running before the days end. So with fresh fuel lines, gas, a new battery, and lots of cleaning both in the bus (to get the stink out) and in the garage (to get the stink out to make the sure we had a decent workspace), I went to bed Friday night, ready to go, but just barely squeaked it all in.

Colin arrived Saturday morning around 9:30. Normally he arrives promptly at 9:00, but limped into the driveway running on only three cylinders after spending a half hour troubleshooting a no spark condition on his #3 cylinder. He did eventually get it running through the course of the day as I undertook tasks on the 79.

The first issue we needed to address before trying to start the engine was eliminating an electrical anomaly I had discovered when connecting the battery the day before. I hadn’t had enough time to chase it down after installing the battery the day before. After some interrogation, we discovered that some prior work I had done to the starter had been done incorrectly. I had understood the starter solenoid to be a push against the starter motor lever when in fact it is a pull. As such, I hadn’t hooked the bar in the starter solenoid over the starter motor lever. We corrected this, reinstalled the starter and I went to the front of the bus, Colin to the back. I turned the key and…nothing. The starter wasn’t whirring when I turned the key to run, but when I turned it to run, no start.

I went through a few more iterations of turning the key while Colin fiddled around in the engine compartment. He could hear that the fuel pump was on continuously when I had the key on. We immediately went to the AFM, prying the lid off the factory seal and finding – curiously – that the fuel pump cutoff lever was not disengaging the contacts when the AFM wiper was closed. Colin corrected that and I turned the key again and sure enough it fired to life, horrendously loud as the lifters pumped up. Last time I had a hydraulic engine sit for a long time it took about 10 minutes of driving (after a long idle) before the lifters quieted down.

Colin has such a great ear, even among the racket, he could hear that a cylinder wasn’t firing. He started pulling plug wires one by one and sure enough, #2 wasn’t contributing. We stopped the engine, replaced the wire, and #2 came back online. After that we started polishing up the ignition system. We pulled the points, filed them down until they were shiny, set the timing, and restarted the bus letting it run for a while to see if the lifters would pump up. They never did fully before we shut it off for the day, but we did use the time to visit with Bleyseng who had brought his 70 Ghia by for Colin to have a gander at.

I’m sure I’m missing some minor things we did to get it running, but I don’t exactly recall them or in what order they occurred. Tape-repaired a NLA hose, something with the auto trans mount, etc. Long story short, it runs, and gained a lot of value in about 5 hours. Much thanks to Colin!

Next steps: reconnect CV joints, adjust brakes, and test drive

When I get back into town, I'll resume the photo details as I work on the bus. I'm in brain dump mode only while away.
_________________
Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[RONIN10]

Shifter Refresh

I've been travelling a lot over the last month, but I was home for three days this past weekend and was able to take some time to improve the status of the '79. It still makes an awful racket when running due to a loose/worn/something not quite right with the front transmission mount. But what the heck, I reconnected the CV joints and went to back it out of the garage, just to see how the transmission behaved in what little time I had before venturing off to Austin for the week.

Unfortunately, the shifter had other ideas as the button wouldn't depress, keeping me stuck in Park. Guessing correctly, that this was a rust/lack of lubrication issue from sitting for 11 years, I pulled the shifter, disassembled it for cleaning, gave it a little paint job to prevent further corrosion, and lubed the slider. It went from this...

to this...

I'm waiting until I get home this weekend to reinstall and give the bus a test drive around the block, but the button works flawlessly now and I don't anticipate any hangups shifting between gears...at least not from the shifter end of things. It's not a full blown restoration of the shifter, but that's not what I'm going for here. Just trying to get things functional at this point.
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Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[RONIN10]

I now have seats:

I also bled the brakes and backed it in and out of the garage. I want to do a valve adjustment (hopefully tomorrow) then a proper test drive will ensue.
_________________
Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[RONIN10]

Been a while since I updated last...

I did take the bus on a test drive and was able to make one 1/2-mile lap despite a serious lack of power. On the second lap, I lost all ability to go forward and had to reverse the bus about 1/4 mile home and then when I reached the little hill my house is on, I could only reverse a portion of the way up it before I couldn't get the torque needed to go further. So...did a little research and a transmission rebuild is in order. Looks like gaskets, clutch kits, and brake bands will set me back about $200 or so. I'll give it a go over the fall/winter as it'll be fun to rebuild the transmission and it seems within my ability. I think that's the cutoff point for me. If this doesn't get it to a reasonable usable state, I'll sell it along or start parting it out.

In other news, I made a little progress on getting the title via the DOL. I submitted a public records request to get the last registered owner's address and sent him a certified letter requesting him to complete a release of interest form. Of course, it's known that the guy has died a long while ago after abandoning the bus, so it came back not deliverable, as expected. Today, I took it to the Washington State Patrol for an inspection, the guy inspected it, but couldn't release the report until I take the returned certified letter to the DOL and get them to issue an approval to inspect form which I can then take back to inspector and get the report, go back to the DOL, and get a title.

Your head spinning yet? A very circuitous process, indeed.
_________________
Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[camit34]

Great rescue!

That's a really sweet Bus!
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In search of a Vanagon
1971 Westy (SOLD)
1971 Deluxe (SOLD)
1967 Freedom Camper (SOLD)

[eche_bus]

I like the stripey look this bus has, but man, you've got your work cut out for you. Clearly exposed to a LOT of moisture. You're going to find corrosion everywhere. Honestly though, if you can get the best of it, you'll have a pretty cool bus, there!

[vwwestyman]

I agree, I love the stripes on this thing!

I just saw the comments about the fuel pump. I would have to say, from my experience, that I'd at least recommend having a spare fuel pump on hand...

Unless you just started dating a girl and want to impress her by singlehandedly pushing your bus off the side of the road with everyone in it when it dies in heavy traffic after a fireworks show because the fuel pump finally died even though it ran fine for a few months after resurrecting it.

Ask me how I know.
_________________
Dave Cook

President, Wild Westerner Club

1978 Champagne Edition Westy, repowered to '97 Jetta TDI
1973 Wild Westerner
My Thing

[RONIN10]

Well, I'm now starting the rebuild process on the transmission. I've got the master rebuild kit for it so now I just have to drop the engine/trans combo and get underway. That'll happen over the next week or so. While I'm in here though I might as well rebuild the CV joints/drive axles:

I also decided to put a video together of it too. Might help out the next stooge.

Link


And all done, ready to be put back in when the time comes:

Cheers.
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Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[RONIN10]

So begins the trans rebuild. First got to get the engine and transmission out:

I remember when I used to have Ratwell up on the computer next to me to make sure I didn't miss anything. After five or six drops now over the years, it's nice to just jump right into it like you're changing your oil. The only surprise this time was just how heavy the engine/trans combo was together; the center of gravity was noticeably further towards the trans end than with a manual transmission.

Trans has now been separated and hoisted onto the workbench and is draining fluids overnight. This is the kit I ended up with:

I recently made some upgrades to my blasting cabinet so I decided to test things out by powder coating some of the tin. I think I'll put the heater control boxes into my '76 with the dump tubes as that's my baby. The gloss black is definitely too shiny, a semi gloss would've been better, but still...so pretty.

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Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle

[wcfvw69]

That powder coated tin looks fantastic. Are you using the Eastwood kit? What's your set up like?
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Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[RONIN10]

[wcfvw69]

That's a nice set up ya got there. I have the same Harbour Freight blast cabinet. I'm jealous of your air compressor. I don't have 220/240 volts in the garage. I need to crack my wallet and have an electrician run some power to it.

Someday..
_________________
Contact me at [email protected]
Follow me on instagram @sparxwerksllc

Decades of VW and VW parts restoration experience.
The Samba member since 2004.

**Now rebuilding throttle bodies for VW's and Porsche's**
**Restored German Bosch distributors for sale or I can restore yours**
**Restored German Pierburg fuel pumps for sale or I can restore yours**
**Restored Porsche fuel pumps or I can restore yours**
**Restored Porsche distributors or I can restore yours**

[RONIN10]

Well, after two journeys into the transmission, I haven't been able to identify the issue causing the lack of forward gears. The first time in I found a broken diaphragm spring in the forward clutch, replaced that along with all the seals and reinstalled. No luck. The second time into the transa nothing seemed out of place. A transmission specialist could probably find the issue in five minutes.

So I'm placing it up for sale to move it along to the next person who can maybe invest in it a bit to take it to the next level. For now, I have an engine rebuild to get underway on my other bus. Interested parties, please go here.

If it doesn't sell, I'll go ahead and pull the transmission again and put it in with a transmission specialist, get the engine humming, and relist it, albeit at a noticeably higher price.
_________________
Andrew

Oscar: 1976 Westfalia Deluxe Camper, 2.0L FI, Manual Transaxle