Replacing the Distributor Gear With Plug

[Red5]

I bought this kit from CBPerfomance as part of the process of going to a Megajolt ignition. The instruction states that the distributor gear should be removed before putting in the plug that covers the distributor hole. Of course, I had put that gear in the motor months ago.

I purchased the special gear-pulling tool. From what I've seen, getting the gear out should be a fairly simple process. I've read through the tips and tricks to getting the gear out (e.g. rotating the crank slightly as you pull on the gear), but that gear does not want to move. I can get it out far enough so the distributor gear no longer meshes with the gear on the crank, but it won't move out any further than that.

Rather than split the case to get this thing out, I'm wondering how terrible a crime it would be to just leave the distributor gear where it is. The plug seems to be long enough to prevent the gear from jumping around while running. I don't see what harm it could do otherwise. But there must be a good reason for CB to insist that it needs to be removed.

Any advice appreciated.

[chrisflstf]

I would not leave it in suspension like that, if it falls, you will destroy the motor

[slalombuggy]

Having one part spinning against a stationary part with little to no lubrication.....what could go wrong?

Push it back down, clean up the bore with a scotchbrite pad wipe it out and pull the gear. Laziness will ALWAYS bite you in the ass.

brad

[oprn]

^^^ It's hanging up on dirt or corrosion in the hole. And don't forget there is thrust washers at the bottom of the hole too. that have to come out.

[Cusser]

You did remove the fuel pump stand before trying to pull the distributor drive gear, right?
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1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297

[jeffrey8164]

If you have to leave it in, I would leave the distributor as well. Better safe than sorry. It “should” come out with the tool but sometimes they don’t. Not sure why. Most of the ones I’ve removed have been with the engine split and even some of those want to stick.
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Volkswagen!
Turning owners into mechanics since 1938.

“Let he that is without oil throw the first rod”
(Compression 8.7:1)

[Red5]

Yep, the fuel pump is off. I will try giving the surrounding area a good cleaning. It does feel unlubricated/dry. I'm mostly frustrated, as this is yet another unexpected setback in a long line of other setbacks.

[Krochus]

I left mine in and just cut down a worthless 009 into a dummy. A 3/8 washer will pound onto the splined part of the dizzy shaft where the advance plate was.
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1970 Turbo Baja Bug Turbaja 2165 t3/t4 Speeduino sequential EFI LS3 coil on plug ignition

1965 Chevy c30, Microsquirt turbo aluminum 5.3/nv4500

[Krochus]

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1970 Turbo Baja Bug Turbaja 2165 t3/t4 Speeduino sequential EFI LS3 coil on plug ignition

1965 Chevy c30, Microsquirt turbo aluminum 5.3/nv4500

[Cusser]

[mark tucker]

the thrust washers are hanging up on the brass gear...... eye wood just put a dist in and some wires to make it look like normal...but leave 2 wire off or put 2 wires on to cap going from 1 to 3 &2 to 4 on the cap with 6" long wires. that will really confuze the exspurts. just tell them it's a wireless lost spark recycling flux generating prototype system from mds.

[M. Notary]

Why does it feel like I am being poked in the eye when I read these replies?

[mark tucker]

must be the way you are taking it.no offence intended. or do you have a 3D computer screen..... do you know witch dist drive shaft you have in the engine? 1 go's in&out at any position...the other only go's in&out in 1 position....that one is a pain in the ass.I still think it's the washers hanging up.

[M. Notary]

[PumaVW79]

When I did the rebuild of my engine, I wasn't able to install the dist gear in the correct direction. The wires on the distributor cap ended up crossing each other, but I just leave it alone, since the engine was working just right.

After some time, when working on the distributor I tried to remove the gear with the help of one piece of wood that I carved the tip to fit tightly on the "head" of the gear. The thing did not move so I gave up.

After a year or so I was again servicing the distributor and decided a new try. This time I’ve used a part of an old gasoline tubing that I replaced a few months before. It fitted very nice with good interference, but the gear hasn't moved, just like the first time. Tried again, this time turning the pulley a very small amount counter and clockwise at the same time checking if the gear was disengaged.

With few trials, I finally felt the gear moving in the direction to the top. Then I carefully and slowly pulled it with a twisting movement. I removed and reinstalled the gear a few times until found the ideal position of the slot to the distributor.

I haven’t removed the washer below the gear but I think it is also easy. I would use the same piece of tubing and inserted it in the hole dedicated to the bottom of the gear. That way, the washer is not able to fall inside the engine. Then a magnet can be used to “fish” the washer and drive it to the top, trapped by the tubing up to the place that it is safe to remove definitively.
In my engine, there is two of them.
That is, in fact, the reverse order as explained in BugMe video on how to install the washer after the engine closed.

[M. Notary]

Is it just me or does every engine in this post look like a hack job?

[mcmscott]

[Zundfolge1432]

Sad but the correct tool isn’t that expensive, makes you look less hackish when you use real tools. Sometimes the washers under the drive cause the hang up. You can remove the fuel pump, remove the phenolic spacer/ mounting block the carefully while using the tool unseat the washers from the gear. Yes they will stay in place you will be using both hands. To unseat the washers use a long small screwdriver or pick.

[mark tucker]

then after the gears is out and the washers are still there use a magnet stick to get the washers out...do not leave the washers in there!!!

[PumaVW79]