Front beam leaves and shift rod coupler removal

VW_MAN_73

Hi. Iam trying to pull the leaves out of my bus beam to put in my narrowed beam and they won't some out. I loosened one of the nuts on the lower beam tube but looks like there is another screw that uses an allen key and I have a 6 and a 8 and they don't work. How do these come out? Thanks. Craig.
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’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
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VW_MAN_73 · Posted: Tue Jan 09, 2007 10:54 pm Post subject:

got the bottom leaves out from the help of hoodride but the shiftrod is in the way on the top one and there is no way in hell that I can get the shiftrod coupler off. Sprayed it in pb blaster for a few days, then torched it and then had to drill out the screws and still won't come off Shocked

I decided that iam going to cut the shiftrod but cant find anything small enough to get in there. I wish I had a sawzall Sad

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’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

Clara · Samba Member Joined: June 14, 2003 Posts: 12663

step away from the bus.
put down the tools

do a search about getting the shift rods apart. The topic comes up here from time to time.
use your Bentley manual.
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VW_MAN_73 · Posted: Wed Jan 10, 2007 12:45 am Post subject:

galexander · Posted: Wed Jan 10, 2007 8:14 am Post subject:

I had a stuck coupler also, used a Dremel with the small cutoff wheel, sliced right through the old coupler. Then was able to use a hammer and punch to knock the old coupler off the rear shift rod, and after pulling the front shift rod out, was able to do the same on it. Just be careful when slicing through the old coupler not to cut into your shift rod. Took like maybe 4 minutes of cutting. Put a new coupler on, after applying anitseize to the shift rods, inside the new coupler and the set screw. Then safety wired the set screw. WW has the couplers.
Good Luck.
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Clara · Samba Member Joined: June 14, 2003 Posts: 12663

derv · Posted: Wed Jan 10, 2007 11:22 am Post subject:

I suggest changing the name of this thread to something relating to the stuck shift coupler so Clara's information wont go to waste.
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Jack

VW_MAN_73 · Posted: Wed Jan 10, 2007 11:28 am Post subject:

I think that would be good but I don't know how to change the topic.
_________________
’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

Stocknazi · Samba Member Joined: June 18, 2004 Posts: 5561

yeah, do what clara said!! she is right on. the hot/cold technique has to be one of the best tricks i have picked up from the samba, bar-none. it works almost everytime. although the process may have to be repeated several times for the most stubborn fasteners, it works 95% of the time. it is defiently alot less headache than having to look for other parts b/c you fu*cked yours up by getting in a hurry. use bp blaster too. i would suggest keeping your bus stock height with stock componants, but it seems you already have it in your head to lower your bus, that's just my opinion. make sure you keep all your og stuff so your bus can be returned to stock later if needed. good luck and take your time
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VW_MAN_73 · Posted: Wed Jan 10, 2007 12:52 pm Post subject:

Yeah, I don't really care for the appearance of stock height. I have a 4 inch adjustable beam with drop spindles that iam working on now. I lowered the rear but have an aftermarket exhaust that is about 4 inches from the ground. Once I get a stock exhaust i will drop it another 2-2 1/2 inches. Here is a pic of the rear. I put the can of easy off so you could kinda see.

Image may have been reduced in size. Click image to view fullscreen.

_________________
’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

VW_MAN_73 · Posted: Thu Jan 11, 2007 1:05 pm Post subject:

I can't take this any more! Evil or Very Mad

I cut one side with a dremel and cant get to the other because of no room. I don't know how you guys get in there. I broke down as of now. Out comes the air cutter and the shiftrod is going to be cut. It may take a while because that things worthless but I can't let this damn coupler stop me from getting this on the road. I have to get this ready for a show coming up way down in miami. Thanks for all your input everyone and I will let you know what it looks like when its done.
_________________
’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

my65vert · Posted: Thu Jan 11, 2007 1:56 pm Post subject:

No, you dont have to cut the other side of the coupler. Just one side, then jam a screw driver into the cut slot and pry the coupler open.

Or cut another slot right above or below the other and take that section out.
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Kombisutra;
I'm starting to get little wafts of bus stink coming from the north. Something about the unique scent of drivers seat padding when it's glued together with mouse piss and shit that really gets me going... and I'm smelling it! Oh yeah! Time to start loading up the equipment.

VW_MAN_73 · Posted: Thu Jan 11, 2007 2:55 pm Post subject:

The dirty deed has been done. The rod is cut Twisted Evil

But the damn beam still won't come out because all the tie rods are frozen. I took out all the nuts on the tie rod ends and they won't pop off. I tried punching them through with a mini sledge and using heat and pb blaster and they still won't come out. Are they any other ways I can free them up?
_________________
’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

Riff Raff · Posted: Thu Jan 11, 2007 3:07 pm Post subject:

Even with the shift rod cut, you still need to get that coupler off.
You will never get the tie rod ends off without a pickle fork (Not good) or a proper tie rod removal tool (Much better). It has been awhile since I have been under my bus, but I didn't think the tie rods had to come off to drop the beam?
Regardless, you will need the removal tool for the drag link anyhow.

Did you cut the shift rod at an angle so you can line it back up properly?

On a side note, you will want to replace that louvred deck lid with a stock one before driving any amount. The louvres will allow the exhaust and hot cooling air to recycle into the engine compartment.
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The greatest obstacle to discovery is not ignorance, but the illusion of knowledge
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VW_MAN_73 · Posted: Thu Jan 11, 2007 3:23 pm Post subject:

Riff Raff · Posted: Thu Jan 11, 2007 3:47 pm Post subject:

VW_MAN_73 · Posted: Thu Jan 11, 2007 4:45 pm Post subject:

hey riff raff. I got that drag link off, I guess thats what its called. Now. How do I disconnect the heater cables and clutch cable? Do I have to take it off at the front or rear? I didn't know that the brake line and heater cables and clutch cable were going through it too Mad

I guess vw never wanted us to slamm buses Laughing

_________________
’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

Riff Raff · Posted: Thu Jan 11, 2007 6:21 pm Post subject:

I don't think the heater box cables are threaded through the beam.
The clutch cable undoes at the front, there is a small pin with a cotter pin through it that needs to be removed.
The e-brake cables can be undone at the base of the e-brake lever and pulled down.
Don't forget to unhook the speedo cable from the drum as well.
_________________
The greatest obstacle to discovery is not ignorance, but the illusion of knowledge
- Daniel Boorstin

VW_MAN_73 · Posted: Thu Jan 11, 2007 6:33 pm Post subject:

thanks riff. All that is done now. Here is my problem. Iam trying to push the shiftrod thorugh the front and its hitting the e brake thing. What do I do about this? All I have to do is that an iam done Smile

_________________
’73 Beetle - My first car, owned 26+ yrs
’71 VW Westfalia - Road-tripping across the US
Rescued & restoring a ’61 Dove Blue SO23 Bus
Follow our journey!

Riff Raff · Posted: Thu Jan 11, 2007 6:55 pm Post subject:

The rear shift rod has to come out through the back.
Now is when you have to get that coupler off.
_________________
The greatest obstacle to discovery is not ignorance, but the illusion of knowledge
- Daniel Boorstin


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Front beam leaves and shift rod coupler removal
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