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Syncro Decoupler wonít disengage. Stuck in 4wd.
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casey79westfalia
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PostPosted: Sat Sep 28, 2019 11:36 am    Post subject: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

So Iím wrapping up my syncro restoration and just installed new vacuum actuators on the rear locker and decoupler. I put a vacuum hose on the vacuum actuator to the decoupler to manually move the pin in and out using my mouth. The pin went in just fine but wonít come out no matter how hard I suck! Ha. I can see it pulling when I suck just doesnít pull the pin out of the bore. Not sure how much vacuum it needs but seems excessive. Everything is new. I am turning the prop shaft while sucking hoping the pin will release. Basically itís stuck in 4wd. Engine is not running yet so I am trying to disengage 4wd. Am I missing something?
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candyman
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PostPosted: Sat Sep 28, 2019 11:59 am    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

What switch are you using in the decoupler? A lot of venders are supplying decouplers with reverse switches instead of proper decoupler switch like whats installed on your rear diff lock. Thus is an issue as the reverse switch requires a lot of pressure for the shaft to move with in it. I found this out the hard way. And once i installed the proper switch, the shaft actuated as it should. Quick test, back out your switch a couple of turns and then try to activate the diff lock. The light will stay on but you are just checking to see of the shaft moves without interference from the switch itself. If it works, then theres your problem. If not, then you must have a vacuum issue. I put my money on the switch.

I tested both switches and the reverse switch needed like 9#s of pressure to activate and the decoupler switch needed like 3#s of pressure. I did this by using a scale so not too scientific. I emailed my results to VC and they sent me the proper switch, but this was 5 years ago before the merger.
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casey79westfalia
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PostPosted: Sat Sep 28, 2019 12:55 pm    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

Candyman itís engaged. All four wheels are spinning so itís in 4wd. I canít get it to disengage. I have removed the switch on the side all the way. I can even grab the boot covered shaft of the actuator with my fingers and I am pulling but it wonít disengage. Van doesnít run yet. Not sure what else I can try. I have tried spinning the wheels endlessly hoping it will pop out. This is a brand new decoupler.
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66 Westfalia
87 Westfalia Syncro "Phoenix"
88 Double Cab
76 Porsche 914
2014 Audi Q7
2010 Tdi Sportwagen

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(Rear seat and pedestal, bumpers, mirrors)

http://www.baycountrymotors.com

My 87 Syncro Westfalia 1.8t Restoration

http://www.thesamba.com/vw/forum/viewtopic.php?t=418933

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MarkWard
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PostPosted: Sat Sep 28, 2019 1:22 pm    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

So you unbolted the actuator from the bracket and you still canít manually pull the shaft to uncouple it? I had a problem with my rear locker and made a tool that looked like a T handle. Using the roll pin to attach it to the shaft I was able to lock and unlock manually while I figured out the problem. 2 copper washers under the switch and the shaft freed up. If you canít figure it out externally, Iím afraid it needs to come off to see whatís hanging up. Sorry
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casey79westfalia
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PostPosted: Sat Sep 28, 2019 1:38 pm    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

I canít reveal the roll pin. It would need to disengage for me to get to it. When engaged the pin is inside the bore. It went in so easily but doesnít want to come out.
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66 Westfalia
87 Westfalia Syncro "Phoenix"
88 Double Cab
76 Porsche 914
2014 Audi Q7
2010 Tdi Sportwagen

Currently looking for 62 Double Cab, 66 Westfalia Parts!
(Rear seat and pedestal, bumpers, mirrors)

http://www.baycountrymotors.com

My 87 Syncro Westfalia 1.8t Restoration

http://www.thesamba.com/vw/forum/viewtopic.php?t=418933

"Do it the right way, or you'll pay for it"
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MarkWard
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PostPosted: Sat Sep 28, 2019 1:46 pm    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

So with the actuator in your hand unbolted from the bracket you canít pull the shaft out? Any chance the roll pin was protruding out one side of the shaft? Thereís no secret to this. If you canít get the shaft back out, youíll need to remove the housing.
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casey79westfalia
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PostPosted: Sat Sep 28, 2019 2:09 pm    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

Victory! I was able to get the pin back out and van is in 2wd again with some serious pulling on the actuator. I removed the pin and the actuator. I then did similar to what markward mentioned. I took an old broke actuator housing apart that I had on the bench and used just the long drive pin under the rubber boot with vice grips attached on the other end. I then reattached to the decoupler drive pin. After working the pin in and out on the decoupler a few times I noticed a little trans fluid seeping out of the switch hole I had removed on the side. Then it dawned on me I just added trans fluid to the trans yesterday but this van has never been driven so decoupler was fluidless inside. The pin was dry. Working it in and out lubed it up. Thatís what she said!. The more I worked the decoupler push rod the smoother it got. I can now activate the setup with the actuator by using my mouth to engage and disengage with the vacuum hose. Total success!
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66 Westfalia
87 Westfalia Syncro "Phoenix"
88 Double Cab
76 Porsche 914
2014 Audi Q7
2010 Tdi Sportwagen

Currently looking for 62 Double Cab, 66 Westfalia Parts!
(Rear seat and pedestal, bumpers, mirrors)

http://www.baycountrymotors.com

My 87 Syncro Westfalia 1.8t Restoration

http://www.thesamba.com/vw/forum/viewtopic.php?t=418933

"Do it the right way, or you'll pay for it"
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casey79westfalia
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Joined: May 22, 2003
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PostPosted: Sat Sep 28, 2019 2:21 pm    Post subject: Re: Syncro Decoupler wonít disengage. Stuck in 4wd. Reply with quote

One thing I do notice is that it engages easier in certain spots on the wheel rotation. Not sure whatís normal. Thereís an area of the rotation where itís pretty effortless but other areas in the rotation itís much harder and then other spots where I canít push it in at all.
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66 Westfalia
87 Westfalia Syncro "Phoenix"
88 Double Cab
76 Porsche 914
2014 Audi Q7
2010 Tdi Sportwagen

Currently looking for 62 Double Cab, 66 Westfalia Parts!
(Rear seat and pedestal, bumpers, mirrors)

http://www.baycountrymotors.com

My 87 Syncro Westfalia 1.8t Restoration

http://www.thesamba.com/vw/forum/viewtopic.php?t=418933

"Do it the right way, or you'll pay for it"
Back to top
View user's profile Send private message Send e-mail Visit poster's website AIM Address Instagram Gallery Classifieds Feedback
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