Oil gallery threaded instead of plugged what does that mean?

[kingkitesurf]

I am lurking this rich resource of knowledge while I am rebuilding my type 4. It is split and all apart. I read here about drilling and threading the oil gallery to replace the plugs while it is apart. Sounds smart....but what plugs are we talking about and where are they located.

[busdaddy]

Some helpful links here: https://www.thesamba.com/vw/forum/viewtopic.php?t=608894&highlight=gallery+plugs
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[timvw7476]

They are caps peened over the drillings in the case that deliver oil everywhere.
There are some at the main seal end, some near the oil pump mount,
and two tiny ones at the end of the oil cooler flange,
After twenty years/120,000 heat cycles they can blowout or begin to seep.
This leads to an oiled clutch disc,lost oil & oil pressure & a Bad Day When It
Happens. Threaded aluminum plugs are one way to avoid that Bad Day.

[SGKent]

threaded steel. You'll never get threaded aluminum ones out again if you need to. They gall.
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[Wildthings]

[kingkitesurf]

So where are they located... I have the engine in pieces here

[Wildthings]

I know there is a good thread on this on the Type4um at Shoptalkforums.

[Wildthings]

I know there is a good thread on this on the Type4um at Shoptalkforums. IIRC, there are 11 different plugs in three different sizes: 1/8. 1/4 and 3/8" NPT.

[kingkitesurf]

So? Do the experts here suggest to extract and replace all those 11 plugs for threaded ones... that is a massive job with significant risk.

[Wildthings]

It takes three drill bits and three taps all of the correct sizes. I ground the shanks on my drill bits so I could turn them in slowly using a large tee handle the same as used for the taps. The three largest ones behind the flywheel are the most likely to blow, but doing them all give peace of mind and allows you to flush out the oil galleys more effectively.

As I said above there are some very good articles on the Type 4rum at Shoptalkforums.com about doing this.

[timvw7476]

Image #1: two right of cam plug, plus the one on the lower left is welded up.
Image #2:can't be seen in the image but they are at the end of the oil cooler
mounting 'ear' & they are tiny.
Image #3: two at the left, by the oil filter mount mounting pad.
Image #4: none, but if it were a dual-carbed engine case, you would want to
at least keep the fuel pump rod in the case to maintain proper oil
pressure/delivery, even when not running the factory mount pump.
The reason for the welded one is the allen plug tends to partly block oil flow,
so some shops weld it closed instead. (at least that's what I recall)
Also, some have had the plug near the oil filler/dipstick mount work loose,
I've never experienced it but it happened to someone, somewhere. FWIW.

[Wildthings]

[raygreenwood]

I have not needed or used drll bits for any of the galley plugs in ages.

Use a dremel tool, a carbide burr (where needed) and 1/4" sanding drums for the rest. It allows you to work up to what is needed for the ground off tap fit without worrying about the drull bit hanging up, bottoming out or doing damage.
Ray