Autostick control valve disassembly & inspection

[heimlich]

Very well done. Now we just need to source the parts for a rebuild.

[Tom K.]

I am in the process of refreshing my '71 Super Autostick. I have the control valve out, and followed these crystal clear directions for disassembly. Although reassembly was pretty easy, I thought this thread needed a completion to help save future autosticks. So here it goes.

Here is the control valve before anything was done to it other than removing the bracket.

After disassembly, my first task was to attempt to source new seals and o-rings. Here is a picture of the complete set (only one of the two 8mm o-rings made the picture). I taped these to my journal book to take to the hardware store

My hardware store had several drawers of o-rings in metric sizes, I found some of them for about $2.

But I wasn't happy with the fitting -- and the hardware store o-rings were not square cut like some of the originals. So I ended up using none of those. I then found the website "The O-Ring Store" and made an attempt to match what is needed. The o-rings arrived in a few days with a tootsie roll included

Here is the manifest. Often the minimum order requires more than one but not that many - the whole order was about $5 plus S&H. The tootsie roll disappeared about 30 seconds after this picture was taken.

I used some of these but not all. In particular, the 32mm thin O-ring was too thick, and the 24mm seal was not perfect either. So I ended up using about half of the original seals and O-rings. Maybe someone else can take better measurements in the future and order better replacements.
So on to the rebuild. I tried to use the same camera angles as sb001. Each photo has the housing and also the pieces that are about to be added in order.
Step 1 is to add three o-rings

Step 2 is to add the check valve and check valve spring to the hole on the left

Before dropping these in, you can snug the check valve into to the spring and add as one.

Here they are resting in the hole - take a notice of the side of the check valve that faces up away from the spring - the two sides of this valve are not the same.

Next secure the diaphragm housing to the valve housing using the two screws that had given sb001 some trouble.

These went in and out pretty easy for me, and my screws did not have any crud like for sb001. But I did use my very long screwdriver to get these in good.
Once your diaphragm housing is in, then drop in the plastic spacer and the seal (I could not source this seal and thus used the original)

Next, it's time to add the diaphragm and support (in one piece - as the sb001 learned the hard way - I would have *definitely* ripped mine too if I didn't read this post!)

This just drops in. Spend a moment to gently tuck the edge of the diaphragm snuggly into the housing.

Next situate the spring and the cover and tighten the four screws.
Now its time to flip the housing on a new side and add the reducing valve and its components. Here they are laid out.

Note that the side of the valve with the small red circle faces up. The spring is sandwiched nicely between two retaining plates. You can snug these three together before dropping into the hole after the valve.
Then you can add the cover, washer, and cap. The washer needs to be pinched to fit within the side groove in the housing thus securing the cover

Before adding the plastic cap, screw the adjusting bolt until 2 threads or so remain visible. You will want to adjust this later once the car is operating to prevent too much or too little clutch grab. Yes, my retaining washer was not all the way in yet - I went back and snuggled it in after taking the picture.

Flip the housing over again to drop in the main valve and its components. Here they are laid out ready to go in.

I dropped the 24mm sealing o-ring in first, using my original because I never came close to sourcing it. This is what it looks like before adding the final seal and the solenoid spring.

You're now ready to install the solenoid. This was the only step that took some effort - but not much. You need to really press down against the spring to thread the four little screws.

I was able to get it in without too much effort - holding one side down with my hand and pushing hard on the screw with the screwdriver with the other hand until we find threads - then twist.
Here is the final product ready to be installed with new vacuum hoses. I left the air filter off, because I still haven't soaked it for cleaning yet.

I hope this might help other complete this job. If anyone can do a better job than I at sourcing the o-rings, then please share what you found.
_________________
'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[sb001]

Nice addendum to the thread Tom- I was lazy and told folks to just put it back together the same way it came apart but the pictures and step by step really help.
_________________
I'm the humblest guy on this board.

1969 autostick sedan, family owned since new
1600 SP engine
Solex 30 PICT 3 carburetor
Bosch 113905205AE autostick distributor

[volksworld]

fwiw the "crud" on the diaphram housing screws was loctite....thats why they were hard to remove...and to prevent an air leak down the threads (although i think they go into a blind hole where that shouldnt be an issue) dunno, dont have one apart in front of me....

[mercmad]

[ClaudiaRibas]

Hi! I just bought a Ghia 1970 convertible Auto Stick. I am working on it by myself. Watching videos and reading books. I am stuck in the Control Valve. I think I need a new one. Mine is in bad shape. Does anyone know where I can find one? I searched the web an eBay and they have no. Any help will be much appreciated.
Thanks
Claudia Ribas

[SBD]

[crankbait09]

bump
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1963 Ragtop

[vamram]

WAAAAAY late to the party, but this should be a sticky for Auto-stick owners. I dream of my next Super being an autostick and this thread will likely come into play at some point.
_________________
Eventually, "we are what we pretend to be.’”
Give peace a chance - Stop Russian-Soviet Aggression!!

'74 Super 9/16 - present, in refurb process.
'73 Super - 6/18 - Present - Daily Driver!
'75 Super Le Grande...waiting it's turn in line behind '74.
Click to view image
Save the Supers!!

[wagskeet]

I have a 68 Autostick, where online can I purchase a new control valve or do I have to rebuild it?
Thanks

[Tom K.]

Is your problem mechanical or is the solenoid not functioning? You can only going these by searching the Samba classifieds. Usually a few are for sale here. If not, then one should pop up soon enough.
_________________
'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[sb001]

[wagskeet]

I have a 68 Autostick, where online can I purchase a new control valve or do I have to rebuild it?
Thanks

[Tom K.]

Um, as I said above, the samba classifieds is the only place other than FaceBook/Craigslist/eBay.
_________________
'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[heimlich]

I can have the orings/etc custom cut. I just need the sizes and then I can put a kit together.
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[Tom K.]

[heimlich]

[Tom K.]

Just encountered this video. He uses a rubber glove to seal various points in the control valve. Creative. This might be increasingly necessary as we go forward.


Link

_________________
'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=

[sb001]

[Tom K.]

Nice score. Having an extra one may be important as we move forward into the next few decades. I'm also going to source a pair of those rubber gloves to keep on hand. And I like how the youtuber says fixing the electric solenoid is the "easy" part. I wish he would post a video on that.
_________________
'91 Vanagon Westfalia
'70 Beetle Convertible
'71 Super Beetle Semi-Automatic: https://www.thesamba.com/vw/forum/viewtopic.php?t=714131&highlight=
'65 Ghia: https://www.thesamba.com/vw/forum/viewtopic.php?t=762478&highlight=