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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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 Posted: Fri Mar 21, 2025 1:02 pm Post subject: Re: '59 Karmann Ghia fever |
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| PeteSC wrote: |
| Perhaps. Your challenges with it still installed would be accurately testing the axle movement for possible binding, and you'd also have to cut the gaskets in order to slip them around the axle, creating possible new leak points in each one and potentially rendering the whole exercise moot. |
Was thinking of still removing the axle tubes so that uncut gaskets could be slipped over the axles. Not sure this is possible or worthwhile— perhaps by that point it would have been easier to remove the transmission completely.
I do remember being informed it was necessary to remove the engine to put on the old style thermostat flap on the back of the fan housing but managed to install it without doing so.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 10749
Location: Pearl River, NY
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| Posted: Fri Mar 21, 2025 3:27 pm Post subject: Re: '59 Karmann Ghia fever |
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| Quote: |
| So next before we put the engine back in |
Clean off the transmission output shaft in the bellhousing with a brass-bristle brush. Get the bristles down into the grooves between the splines to get all the small dirt out. Pull the brush rearwards towards you and wipe the debris off the shaft's smooth end onto a paper towel. Once the shaft is clean, apply a small amount (fingernail dab) of universal grease onto the shaft and splines and spread it all around the splines. A very thin amount is enough. You want to lube those splines because the pressure plate center slides on those during normal clutch activation. |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Sun Mar 23, 2025 7:25 am Post subject: Re: '59 Karmann Ghia fever |
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Well, call me Alice— down the rabbit hole I go!
The transmission is the last system that has gone completely unchecked by me and, given Mr. Happy’s admonition to look at everything on our car after seeing the missing key on the crankshaft pulley, I think it prudent that it be so checked.
Besides, what better opportunity will I ever have to expand my automotive tuition into the workings of a VW gearbox?
Even the darkest night will end and the sun will rise.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Loren 
Samba Member
Joined: January 10, 2004
Posts: 1896
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| Posted: Sun Mar 23, 2025 8:29 am Post subject: Re: '59 Karmann Ghia fever |
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| I would start with a good cleaning. Crawl under the car and try to scrape any thick gunk off first. Then take it to a self car wash and spray the transmission with a good degreaser and let it sit for a few minutes before carefully spraying it off. Maybe with a clean transmission you can better determine where the leak is and if you have to remove the transmission it willl be cleaner to work on. Have you checked the transmission oil level? |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Sun Mar 23, 2025 9:21 am Post subject: Re: '59 Karmann Ghia fever |
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| Loren wrote: |
| I would start with a good cleaning. Crawl under the car and try to scrape any thick gunk off first. Then take it to a self car wash and spray the transmission with a good degreaser and let it sit for a few minutes before carefully spraying it off. Maybe with a clean transmission you can better determine where the leak is and if you have to remove the transmission it willl be cleaner to work on. Have you checked the transmission oil level? |
Thanks for checking in Loren!
Is your Ghia in any danger of cruising the by-ways this spring?
Yes, you are right, I will get under and clean up the gunk. Car wash might be difficult to get to without an engine haha. It would be good to get a better sense of what exactly is going on before removal though. It has been wet since I took over stewardship but began dripping in earnest when I put it up on jack stands to remove the engine.
I am constantly reminded how dependent I am on the good folks of The Samba. Hope I am keeping my end of the bargain up as a source of entertainment.
Will post photos…
So what are the likely culprits? As far as I can determine— overfull transmission, o-ring (if this transmission has such a thing), paper gaskets, axle boots. Might there be some other more dire cause such as a cracked case?
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Loren
Samba Member
Joined: January 10, 2004
Posts: 1896
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| Posted: Sun Mar 23, 2025 1:31 pm Post subject: Re: '59 Karmann Ghia fever |
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There is a chance my Ghia will be drivable later this year (enough for a drive around the block). Funny thing is, I have owned it for 25 years and it has never been drivable : )
Maybe you could roll the Ghia out onto a big tarp and borrow or rent a pressure washer to clean the transmission? I have had good luck with a product called Purple Power cleaner for degreasing. The leak is likely coming from the boots or side plates. I think a cracked case would be very unlikely. I had to fix a leak on my transmission that was from a lock pin near one of the brake backing plates. Never seen a transmission leak from there before, so anything is possible.
At this point don’t sweat it. Get it cleaned and see where the leak is. Might be something simple. Fingers crossed. |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 10749
Location: Pearl River, NY
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| Posted: Sun Mar 23, 2025 2:50 pm Post subject: Re: '59 Karmann Ghia fever |
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| Quote: |
| Crawl under the car and try to scrape any thick gunk off first. |
Use a PLASTIC scraper, not metal! Metal can leave scrape marks or even gouges in the aluminum trans housing. Trans gunk is evil stuff, thick and "clingy" due to the heavier-weight transmission oil (3 x "thicker" at SAE 90 than SAE 30 engine oil) and the road debris. There are many ribs and deep channels around the transmission where you need to dig in with a small scraper to lever them out. Loren's idea of placing a large plastic sheet under the car is good; you can buy a plastic sheet for covering a room floor for painting. The dropped gunk will land on the sheet, and when you start spraying off the trans with the power washer, the loosened "muddy" gunk will also fall onto the sheet. AFterwards you push the Ghia back into the garage and leave the sheet outside so any standing water can evaporate. After a few days you can roll up the sheet starting at the corners, make a pile of it, wrap it with duct tape, and place it with your garbage- or into a garbage bag.
If you rent a power washer, one that sprays hot water will be more effective with the dirt removal than just cold faucet water.
When I'd drive up Rt 7 thru New Milford in the '80's to sometimes visit my cousin north of town, there was a DiY car wash south of town on the right side in the flat lot across the street from the present Tractor Supply. You can still see the concrete foundation. |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Sun Mar 23, 2025 3:16 pm Post subject: Re: '59 Karmann Ghia fever |
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I can’t wrap my head around owning a car for 25 years and never having the pleasure of driving it! I am getting the impression that you are an unusual character Loren.
Will get gunkin’ when its a bit warmer.
So you driving up Rt.7 anytime soon to help out Rome?
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Wed Mar 26, 2025 12:51 pm Post subject: Re: '59 Karmann Ghia fever |
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Got to gunkin’. There really isn’t that much.
The whole transmission is just wet.
Can’t loosen the fill plug so did not drain. I Blasted the fill plug, will try again.
Clearly both boots are leaking. But it seems unlikely to me that that is the only leak given how wet the transmission is— our car has been up on jack stands all winter.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Thu Mar 27, 2025 11:06 am Post subject: Re: '59 Karmann Ghia fever |
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So it looks like the nosecone gasket on the transmission failed (besides the axle boots), right?
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Sat Mar 29, 2025 8:31 am Post subject: Re: '59 Karmann Ghia fever |
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Well, given no dissenting opinions, we seem to be pulling the transmission.
Wish me luck.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Loren
Samba Member
Joined: January 10, 2004
Posts: 1896
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| Posted: Sat Mar 29, 2025 1:03 pm Post subject: Re: '59 Karmann Ghia fever |
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Removing the transmission will make cleaning and resolving the leaks much easier. Be sure to disconnect the battery first  |
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Teeroy
Samba Member
Joined: April 20, 2003
Posts: 3884
Location: Eastern WA
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| Posted: Sat Mar 29, 2025 6:54 pm Post subject: Re: '59 Karmann Ghia fever |
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Hockey stick bushing and detent plugs could be leaking as well
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Pres. Rivercity VW Club www.rcvwclub.org
Founder Derr Wheat Panzers (DWP)
ARR #3
www.autosportsnorthwest.org |
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wagen19
Samba Member
Joined: November 16, 2007
Posts: 864
Location: germany
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| Posted: Sun Mar 30, 2025 1:19 am Post subject: Re: '59 Karmann Ghia fever |
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| Trylon wrote: |
Well, given no dissenting opinions, we seem to be pulling the transmission.
Wish me luck. |
Sorry, hav not watched all posts about leaking oil.
Often the 3 plugs for shift fork locks are leaking or missing.
On older 311 transmissions, they were made of rubber and detoriate.
The original replacement parts are aluminium, 113 311 599
They can be installed while trans is in car.
Location is right side front, but hard to see, just beside the right frame fork.
https://www.google.com/search?client=firefox-b-d&q=113+311+599 |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Sun Apr 20, 2025 3:48 pm Post subject: Re: '59 Karmann Ghia fever |
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Ok, been off in research life.
Back to real life haha— thanks for the suggestions of other leaking points.
Have finally managed to remove the fill plug so removed both drain plugs, black oil is draining as we speak.
Moogie came over and was simultaneously impressed with where I had gotten to and dismayed at where our car still had to get to. Said I had the right attitude though. We’ll see.
Transmission removal next.
p.s. have attempted to apply my newly found mechanical confidence to an ETC check light on my Fiat 500. Cleaned the throttle body and getting a scanner to clear the engine check light. I think I may have found a new career when my retirement funds run out.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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calexican
Samba Member
Joined: June 11, 2008
Posts: 741
Location: El Paso, TX
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| Posted: Mon Apr 21, 2025 6:16 pm Post subject: Re: '59 Karmann Ghia fever |
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way to go michael!!
is it the og crash box? i can't remember when i drove it if it was...
i made the swap on my 58 to a fully synchronized later transmission, and am very glad i did. |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Mon Apr 21, 2025 6:22 pm Post subject: Re: '59 Karmann Ghia fever |
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Thanks John!
The transmission is fully synchromesh. My stock instincts say to put in a split case but I am listening to reason these days.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Tue Apr 22, 2025 1:28 pm Post subject: Re: '59 Karmann Ghia fever |
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Time to check previous work and, well, this doesn’t seem right!
My guess is that the brakes are not adjusted far out enough.
What’s yours?
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel! |
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Rome
Samba Member
Joined: June 02, 2004
Posts: 10749
Location: Pearl River, NY
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| Posted: Tue Apr 22, 2025 3:08 pm Post subject: Re: '59 Karmann Ghia fever |
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| Quote: |
| The transmission is fully synchromesh. My stock instincts say to put in a split case but I am listening to reason these days. |
Keep this transmission! Having a fully synchro'd 1st gear is practical for low-speed driving. Think back to your classic car drive at the Lime Rock vintage weekend a few years back, slowing down for turns in town, etc. And how smooth you could drive off with the synchro'd 1st gear. Or when driving in your town with all those stop signs. It's an upgrade that is not directly visible, and you know it works. Too bad you need to pull the transmission out anyway for that nose cone seal, but you're putting an otherwise known good part back into the car.
It's similar to Moogie32's '63 Ghia's 40 hp engine. You probably know it has a big bore kit for 1385 cc but the engine looks stock. So that engine, and your synchro trans are "hidden benefits". |
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Trylon
Samba Member
Joined: August 16, 2019
Posts: 4983
Location: Connecticut
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| Posted: Wed Jun 11, 2025 12:12 pm Post subject: Re: '59 Karmann Ghia fever |
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Yep, still at it! Somehow I have become the caretaker of three automobiles though.
Had to replace the throttle body in my Fiat 500.
Replaced the ignition switch housing in the 914 and made it better able to handle pop-up showers by installing the rain tray and funnels.
Back to our car today to wrestle with transmission removal. It’s funny, I know there are many out there in SambaLand that wonder what the heck I am doing. They would have gotten the engine out, taken out the tranny, repaired the clutch and transmission seals and put it all back together well, if not in an afternoon, a weekend. It is so slow going for me because I simply have not done this before and each bolt, connection, task always seems to have some trick up its sleeve that I must uncover— like an Infocom game.
For instance, it took me at least an hour to figure out how to remove the square head set screw that holds the shift coupler! And then, I needed to consult with ChatGPT to finally make it happen.
In any case, I am back on this with the probable goal of putting our car up for sale. BTW: This will be the first year since restoration that our car will not be going to the Bug-A-Fair in Terryville. Actually, I think the Karmann Ghia contingency might be happy to see someone else win that class haha.
_________________
1973 Porsche 914 2.0
1959 Volkswagen Karmann Ghia
1979 Volkswagen Rabbit
1973 Volkswagen Bus
1970 MGB-GT
1962 Oldsmobile Jetfire
More tomfoolery on
The Karmann Ghia Fever YouTube Channel!
Last edited by Trylon on Wed Jun 11, 2025 4:17 pm; edited 1 time in total |
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