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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 4014
Location: MD
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 Posted: Sat Jan 04, 2025 7:32 am Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild |
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I'm glad to hear the transmission appears to be in great shape. I would highly recommend changing the oil before you actually drive it, of course. I just bought BG Ultraguard for my Syncro.
The better shape the trans is in, the cheaper it is to rebuild. It can be as cheap as $2300ish. I spent $7k. My trans was not in good shape. I'd really think about the next soonest time it'll be down for a month and send it off for a rebuild. You'll be saving yourself thousands.
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'87 Syncro Ferric Oxyhydroxide Superleggera Edition
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Sat Jan 04, 2025 2:48 pm Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild |
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| 4Gears4Tires wrote: |
I'm glad to hear the transmission appears to be in great shape. I would highly recommend changing the oil before you actually drive it, of course. I just bought BG Ultraguard for my Syncro.
The better shape the trans is in, the cheaper it is to rebuild. It can be as cheap as $2300ish. I spent $7k. My trans was not in good shape. I'd really think about the next soonest time it'll be down for a month and send it off for a rebuild. You'll be saving yourself thousands. |
I will definitely be changing the gear oil before I drive it much. Good to know for the oil, I was going to do some research on it. I recently put swepco 201 in my 71 and was thinking of doing something similar.
I will have to think on that a bit. I’ve seen a lot of issues with rebuilt transmissions so I’m always leary. Before I bought it I was even thinking about pulling the trans to replace some of the bearings in it as preventive maintenance. I’ve had a lot of mainshaft bearing issues in my cars.
This morning was the last chance I had to get much of any work done on it before I head back up to school. I finished adjusting the panel I made and I got it welded in. It turned out pretty good I think.
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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dobryan
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Joined: March 24, 2006
Posts: 17037
Location: Brookeville, MD
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TheGrafs
Samba Member
Joined: May 07, 2012
Posts: 253
Location: Utica, New York
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| Posted: Thu Jan 30, 2025 5:51 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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Dude!! An absolute Gem of a find! Glad to see you got yourself a Syncro! Amazing work on the patches, and glad to see you use weld through primer! 
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Robw_z
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Joined: April 28, 2007
Posts: 987
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| Posted: Thu Jan 30, 2025 6:58 pm Post subject: Re: A 1991 Syncro Single knob “Rome” rebuild |
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| 16CVs wrote: |
Commonly referred to as an "L" model. Most of them were bought by converters to do Pop and High top conversions. Since they were bare bones and cheaper then a Carat or standard passenger van and most came with AC.
Nice find, I've owned a couple of them in 2Wd and have a soft spot for them.
Stacy |
Correct, I've daily driven one for almost 18 years now (2wd version). They were made in Graz, Austria in the former Pinzgauer plant; unlike the vast majority which were made in Hannover.
-Rob |
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16CVs 
Samba Member
Joined: February 22, 2004
Posts: 4202
Location: Redwood City, California
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| Posted: Sat Feb 01, 2025 3:05 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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I think the plug in your hand is for the cruise control pump, does the van have a cruise control signal lever?
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Mon Feb 10, 2025 1:47 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| dobryan wrote: |
| I have used Swepco 210 and 201 and both of those had issues crunching going into 2nd in the cold until the trans got warmer. I now use 202 and no issues. |
Thanks for the tip! I used 201 in my 71 westy and noticed the same. I just ordered some 202 for it
| TheGrafs wrote: |
| Dude!! An absolute Gem of a find! Glad to see you got yourself a Syncro! Amazing work on the patches, and glad to see you use weld through primer! |
Thanks! I am really excited for it and found a really good Syncro it seems. I’m happy with how the patch turned out. Thankfully it doesn’t need many!
| Robw_z wrote: |
| 16CVs wrote: |
Commonly referred to as an "L" model. Most of them were bought by converters to do Pop and High top conversions. Since they were bare bones and cheaper then a Carat or standard passenger van and most came with AC.
Nice find, I've owned a couple of them in 2Wd and have a soft spot for them.
Stacy |
Correct, I've daily driven one for almost 18 years now (2wd version). They were made in Graz, Austria in the former Pinzgauer plant; unlike the vast majority which were made in Hannover.
-Rob |
That’s cool to know! I looked into it a bit and it’s an interesting history!
| 16CVs wrote: |
| I think the plug in your hand is for the cruise control pump, does the van have a cruise control signal lever? |
Ah, that would make sense, I don’t have cruise control so nothing goes into it. Would it be hard to add it?
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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MsTaboo
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Joined: June 02, 2006
Posts: 4502
Location: East Kootenay, British Columbia
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| Posted: Mon Feb 10, 2025 2:47 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| Ceckert64 wrote: |
......
| 16CVs wrote: |
| I think the plug in your hand is for the cruise control pump, does the van have a cruise control signal lever? |
Ah, that would make sense, I don’t have cruise control so nothing goes into it. Would it be hard to add it? |
Actually it's fairly complicated. I stripped almost all of it except the turn signal/cruise control stalk from my Syncro. There are several harnesses, control module, valves, pipes/hoses, vacuum pump, and hookups.
I have all the bits in box (PM me if interested in buying)(EDIT, Sorry sold) but without the stalk not sure how you would be able to control. Would need a stalk from a parted out bus.
The cruise/turn signal stalk does not interchange with the non-cruise stalk on the steering column hub (would need that also) so I had to keep.
There are some aftermarket units that may be easier.
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DocNexil
Samba Member
Joined: January 19, 2021
Posts: 166
Location: Southern Utah
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| Posted: Sun Feb 16, 2025 2:27 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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Pretty awesome to see you taking on a vanagon now!
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Mon Feb 24, 2025 8:15 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| MsTaboo wrote: |
| Ceckert64 wrote: |
......
| 16CVs wrote: |
| I think the plug in your hand is for the cruise control pump, does the van have a cruise control signal lever? |
Ah, that would make sense, I don’t have cruise control so nothing goes into it. Would it be hard to add it? |
Actually it's fairly complicated. I stripped almost all of it except the turn signal/cruise control stalk from my Syncro. There are several harnesses, control module, valves, pipes/hoses, vacuum pump, and hookups.
I have all the bits in box (PM me if interested in buying)(EDIT, Sorry sold) but without the stalk not sure how you would be able to control. Would need a stalk from a parted out bus.
The cruise/turn signal stalk does not interchange with the non-cruise stalk on the steering column hub (would need that also) so I had to keep.
There are some aftermarket units that may be easier. |
Maybe no cruise control then  I’ll keep it simple for now.
| DocNexil wrote: |
| Pretty awesome to see you taking on a vanagon now! |
Thanks! It will be a fun challenge for sure, I’m excited to have 4wd.
I got back from school on spring break and got to work. I started yesterday on the coolant system and the exhaust. I got the stainless steel coolant lines and new rubber hoses. I replaced the plastic junction piece and I found the holes in it, it was strange how it broke. I found the main coolant line had failed too. It looked like after the brass part came out a bit, they reclamped it on the brass part.
I also started to replace the soft brake hoses, all the hard lines are in good shape, no rust on them. My plan is replace those and rebleed the brakes.
The current plan is to drive it back up to school at the end of the week. I have to finish up the brakes tomorrow, replace the CV boot, bleed the coolant, replace fuel injectors and change gear oil to get it all ready. It seems like it may be possible
Thanks to my friend for letting me use his lift. It makes life a lot easier :
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Wed Feb 26, 2025 5:06 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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Yesterday I got the CV joint done with a new boot and regreasing it. The trick I found that works for in the car is shove a bolt with a 10mm head inbetween the clip tangs and then use a pair of vise grips to pound on. I got it out without removing the axle stub as I read that it can screw up the bearing if you take it out wrong.
Then I got all the soft brake hoses replaced and rebled the brakes. All seems good there. The biggest issue is the brake light switch is stuck on so the brake lights are always on. That will get replacement soon.
Today I put in the rebuilt fuel injectors, a new fuel filter and did the great oil change. The gear oil was something   The oil did look too bad but that job is such a pain. Between getting the skid plate off and working to get drain plugs out in tight spot and raising the van up to fully drain it but it now has swepco 202 in it so it should be happy. Here are the drain plugs. The front diff on I had already cleaned off in the picture and the transmission one had the “fuzz” on it.
Then I took it for a longer test drive, it was perfect to start, ran smooth and had good power. It was driving smooth and felt great. I stopped and got gas and when I took off again it started to act up. It would bog if I gave it too much gas and started to seem to miss at higher rpm. I couldn’t get it to go much over 40-45 and then it’d want to bog. Any thoughts on the issues? Fuel related? AFM? I got back and it seems to rev up fine but the issue seems to be under load so I’m thinking maybe fuel starvation when it’s needing more gas and runs out?
I also found the power steering pump is leaking bad and there is a bad coolant leak by the water pump. I looked and realized that one of the bolts holding the pipe on was missing. That’d cause a leak
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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Xevin
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Joined: January 08, 2014
Posts: 8478
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| Posted: Wed Feb 26, 2025 5:28 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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Looking good Aiden.
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4Gears4Tires
Samba Member
Joined: October 08, 2018
Posts: 4014
Location: MD
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| Posted: Thu Feb 27, 2025 8:20 am Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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Did you replace your temp2 sensor? AFM and DME are two other causes. You already took care of the fuel filter.
Interesting way to service the front axles, by leaving it in the strut. I suppose that saves some headache and introduces a few others. I don't think you can damage the bearing by removing it, but you will absolutely wreck the wheel bearing by driving with the front axle removed. Although, if you leave the stub in like you had you can drive it that way.
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Thu Feb 27, 2025 8:50 am Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| Xevin wrote: |
Looking good Aiden.
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I appreciate it, this is the nicest and newest vehicle I’ve ever bought
| 4Gears4Tires wrote: |
Did you replace your temp2 sensor? AFM and DME are two other causes. You already took care of the fuel filter.
Interesting way to service the front axles, by leaving it in the strut. I suppose that saves some headache and introduces a few others. I don't think you can damage the bearing by removing it, but you will absolutely wreck the wheel bearing by driving with the front axle removed. Although, if you leave the stub in like you had you can drive it that way. |
I have not replaced that yet, but I did buy a replacement one for a spare so I’ll give that a try, thanks for the suggestion!
Yeah, it definitely made it a little harder to get out. I was on my friends lift so I could be under it which helped. If I had it sitting on the ground I’d definitely not recommend it. That makes more sense on the wheel bearing. I had just done some quick reading on it so I probably read it wrong.
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Fri Feb 28, 2025 8:59 am Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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I’ve put 120 miles on the Syncro so far Only one break down and it was losing power to the fuel pump since the wire came off. I replaced the TS2 and it did the bogging thing one more time after and then it was good for the last 90+ miles. Maybe just a fluke or the bad fuel pump connection?  It will also idle high on occasion. But it’s driving really nice so far and the heat works good. I got the one coolant leak fixed that was due to a missing bolt and took the power steering belt off since it was leaking bad.
The missing bolt was on the flange to the water pump. Odd place to be missing a bolt
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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4Gears4Tires
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Joined: October 08, 2018
Posts: 4014
Location: MD
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| Posted: Fri Feb 28, 2025 10:34 am Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| Ceckert64 wrote: |
| I replaced the TS2 and it did the bogging thing one more time after and then it was good for the last 90+ miles. |
Maybe the DME adjusting the fuel trims with a working temp 2 sensor, takes a bit. Glad to hear it's running well now!
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Sat Mar 01, 2025 6:09 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| 4Gears4Tires wrote: |
| Ceckert64 wrote: |
| I replaced the TS2 and it did the bogging thing one more time after and then it was good for the last 90+ miles. |
Maybe the DME adjusting the fuel trims with a working temp 2 sensor, takes a bit. Glad to hear it's running well now! |
That’d makes sense, thanks for the help!
Yesterday I swapped the tires from my 71 westy over to the Syncro. I also got my brake lights working right. The pressure switch on the master cylinder wasn’t working right and the brake lights would be stuck on. I added a contact switch to activate the lights.
Today I drove the van up to school, 450 mile trip, no breakdowns but a few hiccups. Only thing was the wire for the temp gauge fell off. It cruised well on the highway between 60-75, I usually kept it around 65-70. It was smooth with no vibrations and it handled good. It felt much better than the Bay on the highway But it did do the bogging thing again. It happened halfway in the trip and I stopped to get gas at the next gas station and then after I shut it off for gas it didn’t happen again. It also had a miss or stubble at 55 +/- 3mph. It also idles high after driving and the idle doesn’t want to drop down but it will occasionally to an average idle. But it didn’t burn any oil, loose coolant, and the temperature stayed constant. It also stayed warm inside. I hit some whiteout snow and wind but it stayed stable. There was also a lot of salt used in the roads sadly  But overall I was happy it made it up fairly well. I’m hoping I can get the issues figured out soon. Last picture is on the Mackinaw Bridge
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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TomInAlaska
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Joined: June 02, 2007
Posts: 469
Location: Anchorage, Ak
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| Posted: Sat Mar 01, 2025 9:52 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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<subscribed>
Good job so far on the Syncro! I am a big fan of mechanical contact swtiches for brake lights ever since I figured out you can definitely apply the brakes enough to slow down but not to actually trigger the lights with the pressure switch. Seeing your pic of the big bridge is making me think about getting pasties at one of the little roadside stands just after you hit da yoopee. 
Also, its crazy how much more now you have there than we have up here. Feeling like spring already.
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Sat Mar 01, 2025 10:23 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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| TomInAlaska wrote: |
<subscribed>
Good job so far on the Syncro! I am a big fan of mechanical contact swtiches for brake lights ever since I figured out you can definitely apply the brakes enough to slow down but not to actually trigger the lights with the pressure switch. Seeing your pic of the big bridge is making me think about getting pasties at one of the little roadside stands just after you hit da yoopee.
Also, its crazy how much more now you have there than we have up here. Feeling like spring already. |
Thank you! It’s been fun so far! The brake light switch upgrade is nice, I can tap it without much of any brakes, and they’ll light up so even just a light tap of the pedal lights them up to get someone back from tailgating.
I should have stopped and gotten a pastie today, soon enough though They all seem to close in the winter time though.
That’s surprising, this week got warm and a lot melted. We had 3ft or more of snow up here in the Kewenaw and it’s down a bit, still a good 2ft or more. Hopefully a good amount of skiing is left in the season.
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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Ceckert64
Samba Member
Joined: September 16, 2015
Posts: 2094
Location: Huntington, WV for now
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| Posted: Sun Mar 02, 2025 7:50 pm Post subject: Re: A 1991 Syncro L Single knob “Rome” rebuild |
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Today the Syncro got a wash, it was covered in salt and there was still moss in spots on it. It looked nice cleaned up.
I started looking into what the running issue was, I was going to start with grounds but I noticed the distributor cap wasn’t attached the one clip had came off so the cap had came loose and rotated messing up timing. The rotor had been eating into the cap and the points in the cap and the rotor got burnt. I went to replace the cap and figured out why the clip was messed up. The clip broke off and I looked and discovered it had been previously broken and another clip had been welded to it so till I can get a new clip I had to zip tie it. The old rotor was also seized on and was a pain to get off, it ended up breaking taking it off.
But after getting it all fixed, I went on a drive and it was running better again and it seemed to take care of the issues. No more stumbles or misses. It still idles a little high but I’m happy it was a simple issue.
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Yellow Tin Top Westfalia -Sold
“Fitz” 1971 Westfalia Poptop EJ22 swap
“Rome” 91 Syncro |
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