Summer engine into 68 Westy - questions

[soissisc]

So every vendor lists this as 25 hp and 36 hp, but this is what came stock on the 1968 1500 engine, right? This is why I have had so many questions in my mind about ordering it.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[airschooled]

[soissisc]

So 6mm it is, tank to carb in my case. Thanks.

My next question has to do with the gas tank. I did a clean up of the inside, although it was not really that bad, and then wanted to take care of some light rust on the outside. I sanded on the outside, more or less to scuff it up and remove any flaking paint so I could treat the rust. Now, I am ready to primer / paint it. I was thinking a satin black rattle can. But once it is all cleaned up it looks more like a gray with blue tint? What color have you all been painting your tanks? This is an early bay.

You can see above, the tank is much "grayer" than the engine tin seen in the background (which is flat or sating black). Or even closer to the antifreeze container sitting in the foreground.

I am going to be going the rattle can paint job on the tank, I wondered if there are any close matches that anyone knows of?

Thanks.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[borninabus]

yes, it's grey and rustoleum makes one that is close.
make sure you get the old school, takes FOREVER to dry rusto.
it lays down nice and is tough as nails once it's fully cured.
be patient and it can come out really good.
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88 Van WBX, A/T - 13 JSW TDI 6M/T - 2012 Touareg TDI Sport

[soissisc]

I was doing some searching, it seems like a Rust-oleum Ford Gray or Massey Gray may be close enough. The Ford may be a little lighter, and the Massey may be a little darker, but I am sure that the paint on the tank has darkened with age and it's environment.

I am going to stop in to the local Tractor Supply and see what they have. An engine enamel or even just tractor and implement paint may be the ticket. I will let everyone know what I find.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

Tank ready for some primer and paint. Those cool factory paint runs are staying!

It is painted and looks good. Massey Ferguson Gray is not exactly the right shade of gray, but it looks a lot better to me and the outer surface rust is pretty handled I believe.

Painted pictures to come..
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

Here is a pic of the finished product after about 36 hrs drying time. I was going to wait to get a pic in the sun so they are apples to apples comparison, but we may not see the sun again for a stretch. So here it is, hanging in the garage on a dreary rainy day with no flash.

I am super happy with how it turned out.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

Hello all, in moving on with the saga, I decided to have a look inside the nose cone for any obvious signs of trouble. I have been reading about the donut being worn, the pinion bearing race sinking into the nose cone, and a few other things. So I pulled the nose cone and all seems well with the exception of the C bracket / pivot pin interface. It seems a bit sloppy on the small diameter end.

The thrust area for the pinion bearing looked fine and the bearing race feels tight in the bore.

I am not sure if adding the metal plate is worth it at this time, or now is the time to do it. I may replace the donut, the seal for the hockey stick, and also that c bracket. Weddle appears to be out of stock on the c bracket.

I'll look a bit closer at everything tomorrow.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

I have another trans here that makes a whirring sound in 1st gear, I am going to pull the nose cone and see what the C bracket looks like on that one.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

I ended up calling Weddle, they had a few in stock that were not listed on the website, so I was able to get everything ordered including the C bracket. Carry on!
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

The parts came in from Weddle. I got the steel plate installed (without machining the nose cone), new paper gaskets on each side of the steel plate, new pivot pin bracket, new steel ball, and new hockey stick seal.

I had to think about if I blocked the vent or not, but I am pretty sure everything is OK there.

Now I need to give the rest of the trans a bath.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

I got the transaxle cleaned up pretty well. I also installed the front mount bracket.

I did have another question. While doing all of the nose cone work, I had the transaxle sitting vertical on the bellhousing (on a couple of 4 x 4's). A bit of gear oil appeared to drip from the input shaft. Would this indicate that I should replace that seal, or would this not leak so much in normal running (horizontal). I have not used this transmission for probably 10 or 15 years, so I don't recall it leaking gear oil in the bellhousing.

I also having a hard time finding any GL4 gear oil locally. I am looking at ordering Amsoil 75-90 GL4 $$$.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

I had a threaded hole in the 002 case for the Bowden tube bracket that was stripped, I needed to take care of that. I inserted a helicoil.

(Before picture only)

Then I cleaned up the CV output flanges of all of the dried up crusty grease (and who knows what else), I noticed some strange wear on the driver's side flange.

(Before pic only)

I sanded down the high spots and called it good. I am going to clean and re-grease the CV joints themselves so I'll look for any weird wear there.

As far as the input shaft seal, I am still on the fence.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[soissisc]

I have a quick question: I noticed some play on the clutch cable arm to the throw-out bearing cross shaft. So when I would push the clutch, the arm would move some radially before the throw-out bearing would actually start moving. Is slop here acceptable? See below for a crude measurement to explain better.

Here it would be at rest:

And then when starting to push the pedal it moves this far before the teeth engage:

And I took all of your advice and went ahead and changed the input shaft seal.

_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)

[Ceckert64]

I’d say that play in the shaft isn’t good. I could be wrong but it should be tight, my one 6 rib that arm is seized on. It would probably be fine but could give out at some point. But I may not be the best reference as my transmissions are usually out of rotted out cars so everything is seized
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1964 sunroof Beetle Restoration "Herbie"
“Joann” 1970 Elm Green Squareback
1972 Sierra Yellow Tin Top Westfalia Camper
“Fitz” 1971 Westfalia Poptop

[airschooled]

I would check for that play with the arm spring tension removed. If it's between the arm and shaft teeth, I'm not sure what you could do besides bulk it up with something like RTV. (Still removable in the future.) The operation shouldn't be affected really, clutch cable adjustment should make it fine.

If the play is in the shaft to bushing area, new bushings are available and the left side installs without any special tools. The right side requires a slide hammer and special drift, but the left side is held in with a bolt and some washers. Bentley has an excellent explored view of early bay bushing setups. There are two sizes, early/small and late/larger, but you'll have to search around to find out exactly how and where to measure.

Robbie
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Learn how your vintage VW works. And why it doesn't!
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[soissisc]

[soissisc]

Pulling that arm on the other trans - no success tonight. Tomorrow is another day.
_________________
Mark

68 Westy
92 Jetta (oh it is retired)
99 Eurovan
05 NBC
06 Audi A3
72 Westy (I am going to fix it up)