Air Cooled VW Beetle and Dune Buggy Technical Articles

Tech Article – Drum brake shoes – replacement and adjustment

Tech Article – Drum brake shoes – replacement and adjustment

Parts you might need - link to category Stock Brake Parts

Warning: The dust created by the brake system may contain asbestos, which is harmful to your health. Never use compressed air to blow it out with and don t inhale any of it. Wear an OSHA-approved filtering mask when working on the brakes. Don t, under any circumstances, use petroleum-based solvents to clean brake parts. Use brake cleaner or denatured alcohol only. Always replace drum brake shoes in pairs, front or rear) – never replace the shoes on only one wheel. Work on one brake assembly at a time so you don’t mix up parts.

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By jcchirco@gmail.com on September 24, 2009 | Brakes, Maintenance | A comment?
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Stock VW Carburetor Adjustment -General Notes

Parts you might need - link to category Stock Carburetor Parts

Before you begin to adjust the carburetor, the valves, points, and timing should be set. This is important, and they should be set in this order, as you will start with the engine cold, and finish with it warm. It’s important to set the valves, points, timing and to check the choke before setting the carburetor, as they all work together for a smooth running engine. Details regarding these settings are given in the links below.

The following descriptions apply to all types of carburetors -
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By jcchirco@gmail.com on | Fuel System
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Air Cooled VW Spring Plate/Torsion bar removal

Tech Article – Spring plate/torsion bar removal.
Submitted by our foum member “treelineracing”

Folks, Don asked me to post this, hope it s of some assistance….
So you need to remove you rear torsion bars, or spring plates, or maybe change the pre-load on the suspension ?
Had the same need myself a while back, and came across some info that may be helpful.
If you already know to do this, or have some other info or suggestions, then feel free to add, ask questions, or provide comment.

Firstly a disclaimer: – the following also is intended to be a guide only, I’m not a trained mechanic,
but I do maintain my own buggy, and have attempted to use both of the following techniques, one more successfully than the other.
If you attempting these activities, you do so at your own risk,
and I accept no liability for anything that may occur, other than the smile on your face when it works correctly.

Parts you might needlink to category Rear Suspension Parts

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VW Beetle Pedal cluster – removal and installation

Pedal cluster – removal and installation

On models that have a manual transaxle, the accelerator, brake and clutch pedals are mounted on a common shaft which is bolted to the left side of the center tunnel. There s no clutch pedal on models equipped with an Automatic Stick Shift – the brake pedal is wider and has two arms attached to a common bushing.

Unhook the clutch cable from the clutch release lever at the transaxle.

Parts you might needlink to category Pedals and Parts

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By jcchirco@gmail.com on | How To's
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IRS Tranny Removal and Replacement

IRS Tranny Removal and Replacement

Place the shift lever in first or third gear.

Take out the rear seat and unhook the negative cable from the battery.

Remove the inspection cover for he shift rod coupling and take out the bolt behind the coupling.

Move the shift lever to second or fourth in order to unhook the shift rod from the coupling.

Raise the vehicle and support it securely on jack-stands. Take off the rear wheels (swing axle models only).

Drain the transaxle fluid.

Take out the engine.

Disconnect and plug the rear brake lines.

Use a chisel to make alignment marks on the spring plate and the axleshaft bearing housing to ensure proper realignment during reassembly, on all models with swing axles.

Parts you might needlink to category Transaxle Parts

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Progressive Weber Carburetor Set Up

Progressive Weber Carburetor Set Up

Progressive Weber

It is important to follow all linkage and lever installation instructions.
The number one and two reasons for tuning errors are improper linkage installations and
over tightened linkage nut, causing a binding in linkage assembly.

CALIBRATIONS MAY VARY DUE TO REGIONAL FUELS AND STATE OF ENGINE TUNE AND PERFORMANCE. POOR RUNNING QUALITY DOES NOT MEAN A DEFECT IN THE CARBURETOR.
AN ADVANTAGE OF THE WEBER CARBURETOR IS ITS EASE OF ADJUSTMENT AND TUNING.

SET UP ADJUSTMENTS

Start set up by confirming carb base line settings.

Do not depend on the factory delivered settings. Check them before the carb is installed.
All settings are done with choke disengaged or warmed up so that the choke is fully opened and disengaged.

Parts you might needlink to category Performance Carburetor Kits

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IDF Carburetors Low Speed Circuit Tuning

IDF Carburetors Low Speed Circuit Tuning

It is most important to verify all linkage and levers are installed without binding
and the linkage opens to full throttle and is allowed to close to the Idle Speed Screw.
This is the number one and two reasons for tuning errors, improper linkage installations and over tightened linkage nut, causing binding in the linkage assembly.

The Individual Runner carbs, IDF, have individual Idle jets and mixture screws for each barrel.
They also have an additional air bleed screws and lock nuts. This is not used for idle adjustment or idle quality.

The settings for these screws should be closed.

Standard IDF Settings:

Parts you might needlink to category Performance Parts

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By jcchirco@gmail.com on | Engine and Trans, Fuel System, How To's, Maintenance
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Carburetor Set Up and Adjustment 34 ICT

Carburetor Set Up and Adjustment 34 ICT

It is most important to verify all linkage and levers are installed without binding and the linkage opens to full throttle position and is allowed to close to the Idle Speed Screw.
This is the number one and two reasons for tuning errors, improper linkage installations and over tightened linkage nut, causing binding in the linkage assembly.

Parts you might needlink to category Stock Replacement Parts

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Re-assembling Rocker Arms

table text goes here Lets get started, we have our new heavy duty rocker shafts and 1.25 ratio rockers. Now we need to assemble them.

Parts you might needlink to category Stock Replacement Parts

Slide the spacer on to the shaft and center it. Then a rocker shim needs to go on each side.

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VW Beetle Shift lever and shift rod – removal and installation

Tech Article – Shift lever and shift rod – removal and installation
Make sure you obtain the correct replacement part if you re replacing the shift lever.
On vehicles produced before August 1967, the lever is straight; it s curved on later models.
Don’t try to swap levers from one model to another unless they re identical.
The lever on 1973 and later models is about 1-1/2 inches shorter than those on earlier models.

Mark the position of the stop plate in relation to the ball housing after pulling back the floor mat and putting the shift lever in Neutral.
This will ensure proper alignment during installation.
Caution: Incorrect adjustment of the stop plate in the shift lever assembly can cause shifting problems.

Parts you might needlink to category Shift Rods and Parts
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By jcchirco@gmail.com on | How To's, Maintenance
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VW Beetle CV Joint – Overhaul and boot replacement

Tech Article – CV Joint – overhaul and boot replacement
Note: The following procedure applies to either CV joint on either driveaxle.
Raise the rear of the vehicle and support it securely on jack-stands.

Take off the driveaxle(s).

Place the driveaxle o a clean working surface.

Work around the outer circumference and dislodge the collar form the joint housing, using a punch and hammer.

Paint or scribe across the components so they can be reinstalled in the same relationship.

Take off the snap-ring form the end of the axle.

Parts you might needlink to category CV’s and Drive Axles

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By jcchirco@gmail.com on | How To's, Suspension
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Installing a Headliner in a VW Beetle

Installing a Headliner in a Beetle
Tools necessary for this job is a pair of sharp scissors, a heat gun (a strong hair dryer will help),
razor blade and upholstery adhesive. Start by laying out the large headliner in the sun for a couple of hours,
as this is one job that is better done on a warm day to keep the vinyl malleable.
Another step you should consider is to sound proof the top.
Installing a headliner isn’t easy, there’s a lot of steps, but it isn’t impossible either.
There is a certain anxiety one feels whenever glue is applied to anything, feeling as
though you’d better hurry before the glue dries and then you’ll be out of luck getting it to stick.
Well, that just isn’t so with upholstery glue as its tackiness depends on heat and time.
Sure it will set up after a few hours, but for 30 minutes or so, it is free to work with.
By taking your time and proceeding thoughtfully,
you will have a professional looking headliner to be proud of.

This task in easier with the seats removed

Parts you might need - link to category Headliners

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By jcchirco@gmail.com on | How To's
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Adjusting a VW Beetle Clutch Pedal


Parts you might needlink to category Clutch Cables

By jcchirco@gmail.com on September 22, 2009 | How To's
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Rear Swing axle boots replacement

Tech Article – Rear Swing axle boots replacement

Place jack-stands securely under the vehicle after raising it.
Take off the hose clamps from both ends of the old boot and cut it off (but don’t bother to remove the screws that attach the seam).

Wipe off the axle tube retainer and the axle tube.

Put on a thin layer of sealing compound to the mating surfaces of the new boot.

Slip the new boot into place, carefully. Be sure not to get oil on the mating surfaces of the seam.


Parts you might needlink to category Axle Boots
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By jcchirco@gmail.com on | How To's, Maintenance, Suspension
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The Different types of Stock Fuel Pump for an Air-Cooled VW

Parts you might needlink to category Stock Fuel Pumps

By jcchirco@gmail.com on | Fuel System
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VW Swing Axle Transaxle Removal

Tech Article – Swing Axle Tranny Removal and Replacement



Parts you might needlink to category Transaxle Parts

Note: You can remove and install the axle tubes and axleshafts with the transaxle installed in the vehicle, but it s not recommended. In order to determine the clearance at the inner end of the axle tube, you need to be able to swing the axle tube around freely. That s hard to do with the transaxle installed on the vehicle. It s also hard to install new gaskets or shims from under the vehicle without damaging them. Lastly, it s really hard to prevent dirt from getting into the differential.

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By jcchirco@gmail.com on | Engine and Trans, How To's
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Exploded View of a Beetle Steering System

Parts you might needlink to category Steering Parts

By jcchirco@gmail.com on | Suspension

Exploded View Early Swingaxle Bearings and Seals

By jcchirco@gmail.com on | Suspension
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Exploded View IRS Rear Bearings and Seals

By jcchirco@gmail.com on | Suspension
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Exploded View of a VW Ball Joint Front Beam

By jcchirco@gmail.com on | Suspension
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Exploded View of a VW Swingaxle Transaxle

Parts you might need - link to category Stock Transaxles

By jcchirco@gmail.com on | Engine and Trans
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Install Link Pin Shims Chart

By jcchirco@gmail.com on | How To's, ID and Charts, Suspension
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Exploded View of an Air Cooled VW Beetle Exhaust

Parts you might need - link to category Stock Exhaust Parts

By jcchirco@gmail.com on | Engine and Trans
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How To Remove and Install a Beetle Clutch Cable

By jcchirco@gmail.com on | Engine and Trans, How To's
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Air Cooled VW Maintenance Schedule

Tech Article – Air Cooled VW Maintenance Schedule

Every 250 miles or weekly, whichever comes first.

Check the engine oil level
Check the windshield washer fluid level.
Check the brake fluid level
Check the tires and tire pressures

Every 3000 miles or 3 months, whichever comes first

Check the automatic stick shift fluid level.
Lubricate the chassis
Change the engine oil.
Check and adjust the engine drivebelt(s), if necessary
Check and service the battery


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Stock 1600cc and 1641cc Engine Rebuild Kit

Parts you might need - link to category Engine ReBuild Kits

By jcchirco@gmail.com on | Engine and Trans
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Performance Air Cooled VW Engine ReBuild Kits

Parts you might need - link to category Engine ReBuild Kits

By jcchirco@gmail.com on | Engine and Trans
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All About Air Cooled VW Fan Shrouds

Parts you might need - link to category Fan Shrouds

By jcchirco@gmail.com on | Engine and Trans
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Locating the Jets in an IDF Carburetor

Parts you might need - link to category Carburetor Jets

By jcchirco@gmail.com on September 21, 2009 | Fuel System, How To's
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Installing a distributor

By jcchirco@gmail.com on | Ignition
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