67 Standard Peach Kombi, West Palm Beach, FL

[don.ville]

Spotted at work.
The image made it's way back to me

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67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[BarryL]

Your ride is glorious. it looks slippery.

[don.ville]

[don.ville]

Checking and replacing the clutch

My side thread on pressure plate condition
https://www.thesamba.com/vw/forum/viewtopic.php?t=795720

_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

Drove to a car show and before driving home the bus was not going into gear easily. I tried adjusting the clutch cable in a parking lot, but it didn’t make a difference,

Might weld this muffler seal before putting the engine back in.

_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

The swing axle boots are holding up pretty good, one side weeping more than the other.

Boot seams should be angled, but are horizontal because my bus is lowered and the axle does not swing that much.
_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

Ordered Sachs KF193-01 Clutch Kit for a 200mm spring centered clutch, pressure plate with the center ring, a throwout bearing and clutch alignment tool.

But I ordered separately the different style clips for the throw out bearing
_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[Stocknazi]

[don.ville]

[don.ville]

Pulled my clutch operating fork out of the transmission.
Cleaned up surfaces, and waiting for clutch kit.

Used a file to clean and chase the grooves for the lever on the shaft

_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

I got the bus in 2008 with a clutch and pressure plate that did not have enough clearance between them for the center ring.
This mismatch worked for over 15 years, and then over the years the clutch would not release fully and shifting got harder over time until finally this weekend the clutch would not disengage and the bus would not go into gear.

I would have to imagine the rubbing would make some sound that was different that maybe I didn’t pick up on.


New clutch kit arrived today.
Inside the SACHS box was a clutch disc with the Valeo logo on it.

See the old on the left and new on the right to compare how the clutch protrusion would fit inside the pressure plate center ring.

The new one fits right in and has enough room to move side to side.

The other fit tightly and didn’t go all the way down.

Scrape mark that shows parts were rubbing that should not be rubbing when the clutch was pressed.
Eventually the pressure plate center would not return to a relaxed position causing the bus to be stuck with the clutch engaged

_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

Installed the clutch today and got the bus driving.

Got new clips for the throw out bearing.

Bentley says there is a specific way to install the old style clips.

I just use safety wire to keep the new style clips in place. They fall out way too easy.

I had to recut the groove for the C-clip since it kept snapping off.

Then followed forum advice and measure the engine case to pressure plate centering ring depth. 62.8mm

Confirmed throw out bearing surface is at least 3mm away.

_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

Clutch back in and the bus is driving like it was before. (thumbs up)

When putting back the tools I took out to check the clutch I decided to get more organized.
I have 2 scissor jacks (one to lift, the other to push down rear axle to remove tire).


I wrapped them in an old t-shirt to stop rattling, and stuffed them in the compartment under the bench seat, the "stashbox".

I put an air compressor, jumper cables, a jump starter box, the two scissor jacks, tow rope, and the jack handle under there.
Wrapped the metal to metal parts with rags.

Pumped up my wide five steel spare, gas can fits inside the spare wheel

Old scrap wood ramps for raising the bus when needed.

Stashed them behind the seat

I have had my bus 16 years and tried the spare on the front, but never tried to fit it on the rear axle.

The lug bolts I had were the wrong type for a steel wide five wheel, and too long, so I ordered some OE style stubby M12x1.5 13mm long ball seat lug bolts VW part # 111 601 139
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67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[j.pickens]

The safety wire is a good idea.
Those clips SUCK!
Look how different your two sets are. And they are supposed to just hang on for dear life?

[don.ville]

[don.ville]

Weekend of Nov 8th, drove almost 4 hours to the 2024 Bulli Brigade at the Quaker Steak and Lube in Clearwater, FL
Attendance was kind of light this year.

Found a guy selling old VW Trends, and bought a copy of Sept 1996 to replace the one I got with the bus.

Left there then drove 30 mins to the Red Bull Flugtag
https://www.redbull.com/us-en/tags/flugtag in Downtown Tampa

Then next day, drove another 30 mins to the 2024 Florida Bug Jam https://floridabugjam.com/, that was crowded as usual.

Good weekend and bus behaved very well, drove 70mph most of the way.
_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

My steering play was very noticeable and getting worse.
I decided to check play by myself.

Removed splash pan,
opened safari windows,
Tied a piece of rope to each side of the steering wheel and crawled under the bus to take a look while moving the rope side to side.

Turns out the rearmost bolt on the drag link was slightly loose.

Tightened it and the steering is much better now.
_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[BarryL]

Very clever. Glad you found it.

[don.ville]

My brake lights stopped working, and I don't know how long they have been that way.

Both pressure switches were bad.

So ordered 2 new switches, and came up with this mount for a mechanical limit switch secured to the pedal.

I used recycled scrap wire, and I made a few extra since I had several of the switches.

https://www.thesamba.com/vw/forum/viewtopic.php?t=803398
_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro

[don.ville]

My Wolfgang safari seals started to separate into two.
The hollow section loosened from the pinch weld section, so I used clear Gorilla glue to reattach the pieces, and closed the window for a day to let it dry.

This is just a cut off test piece, the actual seal on the bus had a long section separated.

Testing the glue on a small section

_________________

67 Standard 11 window How I Keep My Bus Alive
04 Jetta TDI Page (SOLD)
01 Mexican Beetle Hello Kitty Rescue (SOLD)
29 Ford Model A Rat Rod (SOLD)
2015 Audi A8L TDI Quattro