Yes - I have removed the plug to clean out the tank on my 411LE 15 years ago! The alternative is to remove the tank which means removing the front suspension first!

Could be lots of things if its a carb engine, since many aspects are linked in terms of vacuum, idle speed and carb settings. Before assuming the box is at fault you need to make certain the ignition system is spot on including correct timing, distributor advance system is working and no leaks on th...

I've used current thermal type carpet underlay - not the old rubber backed type. Number of offcuts left over after having a new carpet fitted!

I don't think there is any magic number - a lot depends on age and wear within the box also. I was advised to let the box oil warm up and circulate if its been standing a while before putting it under load.

The vac line from the modulator valve runs back to the engine and connects to the balance pipe hard line that runs between the carbs on non FI cars. If it's an FI engine then there must be a similar facility on the intake air assembly.

Stuart Yes I do and the fleet has expanded a bit as you can see! My experiences with the auto box included a rebuilt unit from the US which had a blocked valve body, meaning a lack of lubrication when started which damaged the clutch plates internally needing a full rebuild. You may need an 003 rebu...

Stuart Unfortunately such a sudden failure of an auto box is possible. I understand its usually a consequence of the plates partly drying out after a period of non use and fragments coming off that can block the valve body affecting pressures. However, before you conclude that a visit to an auto tra...

Check you are getting a strong jet of fuel down each carb throat when you open the throttle. You can do this with the air cleaner removed and engine off. If you are not get this you still have a partial blockage.

Your adjustment description is identical to my experience when I did some work on a 66 car last year where the owner had been supplied new disca and (wrong inner) bearings. You can lock the bearing up too tight but even slightly slacker on the adjustment gives the impression it's correct but you can...

The wrong bearing can be adjusted so that under ordinary pressure or movement of the washer it seems correct. If you really give the wheel a good pull it can move in steps, and you get the odd feeling when braking feeding back through the steering.

As I believe your car is a 68 it's worth checking that you have the correct size inner wheel bearing fitted. In 68 VW changed the I/d of this bearing from approx 27mm to 29mm. It's not unusual to be supplied with the 29mm bearing in error which you think you have adjusted correctly but it's still po...

Check for earth continuity between the brass connection point on the inside of the top of the sender and the sender top casting. If this is open circuit it's likely that the rivet holding it all together is corroded, so you need to remake this part of the circuit. I usually drill a small hole throug...

Difficult to describe but if you get used to withdrawing the shafts from the box and see how they fit into the TQ and then fitting them back into the box you can feel when the splines are engaged and should be able to turn them by hand and feel resistance. With the shafts fully in the box you can sl...

Correct. Just make sure the TQ is properly seated on the shafts and does not slip off them before you get the engine back in. Might be worth checking that the shafts are straight before you do and did not suffer any ill effects during the extraction process!

TQ is bolted to the flex plate which is bolted to the crank. When separating the engine from the transmission you have drawn the TQ off the splines of the turbine shaft and pump shaft. Genuine auto engines have the case cut away to enable the flex plate to be bolted/unbolted to the TQ. My experience...

Hope the transplant is successful! Also suggests that a later switch and lock assembly can be retrofitted to earlier 68-70 cars which is useful to know, apart from having to grapple with too many wires!

Mark

I have found the old switch that I removed and am sure was the original. 4 wires as is the replacement the only difference being wire colours. Looks identical to your photo on the right, and think my replacement came from VWH. If you put a screwdriver in the slot you can check how many positions it ...

I did this job on my 68 T34 auto (same column assembly) about 3 years ago. From memory I think you can align the inner part of the mechanism to fit the key drive. However looking at your earlier photo the ignition key assembly with the plastic collar looks like a later 71 on style - that would corre...

I have just bought a new starter for my Auto from ATP in Germany. Found them on the Internet and was about £85 including shipping. Comes with three year warranty and is also listed for various Porsche models. Reckon it was a bargain after seeing a used one at Tatton Park for £120!

Mark

In the VW manual I have for the late 60's there is no dimension, just a template to use to set the pushrod length in situ, following the change from single to dual circuit systems.

Check your voltage regulator output. If this is low it does affect the running of the FI engine. Should be around 14v if I remember correctly. If that checks out fine, then look for vacuum leaks on the various engine pipework, and check that no-one has already fiddled with parts like the pressure re...

If you have no voltage at the coil when the starter is engaged, that indicates a faulty ignition switch. The internal contacts are damaged either mechanically or through arcing.

It's also not necessary to remove the quarterlight glass from the frame, just pivot it open to get to the lower fixing machine screw-the seal has a hole in it to allow the screwdriver to pass through.

Mark

In my experience I would not follow this guide to the letter, specifically it's very difficult to pull the vent frame out with the window outer scraper in position due to the flared end of the frame. By all means remove all the vent frame fixings, including the threaded stud at the bottom of the fra...

Mike As you know last year I had occasion to remove a 200mm 12v flywheel from a twin port 1600 68 engine and transplant it onto a 66 single port 1600 which had the 200mm 6v flywheel. The former had a paper shim fitted and the latter a steel shim. Faced with the same dilemma I started by leaving matt...