Mk1 trans AGONY! FIX, maybe...

[kkrup62 at hotmail.com (Karl Krupke)]

Here's a couple of things to try:

1) Get together all the longest 3/8" extensions you have, borrow if needed. 
You want about 2-3 feet total (I use 2x 12" and 2x 8").
    Put together, with the 12 pt. wrench on the inboard end, for now leave 
the ratchet OFF. Put the 12 pt. in the bolt you're trying to remove, whack 
the outboard end of the stack with a hammer ("whack" is a vague term, "tap a 
few times firmly" might be better. You'll be able to tell by sound & feel 
when the tool is firmly seated in the bolthead). The idea here is to push 
out the gunge & goo that tend to accumulate in the ends of the inner CV 
bolts so that the 12 pt. has got a good fit to the bolthead.
    The outboard end of the extension stack should be out by the brake 
rotor... it isn't stricly necessary but is much more comfortable, and it's 
thus easier to maintain the correct angle (perpendicular) to the bolthead.
    I've done bunches of VW/Audi CV's, this usually works unless the bolts 
have been completely stripped out by some Bubba with an SAE 6-point (which 
is alas all too common).

2) On each inner CV there are 6 bolts, which are paired into 3 washers. FOR 
EACH PAIR OF BOLTS IN THE SAME WASHER, go after the bolt to the right, that 
is CW (clockwise) first. If you can extract that bolt, you can then lever 
the washer CCW with a large screwdriver. That will also turn the remaining 
bolt and loosen it a bit, making it easier to extract.
    A little extra leverage by way of vise grips won't hurt, but be careful. 
Vise Grips by themselves usually won't get enough grip to turn a balky CV 
bolt.

3) Worst case, if you do have to hacksaw the bolts... don't. Get somebody 
else to. Find the aforementioned Bubba, bet him $10 he can't saw through all 
six bolts in less than 30 minutes... go have a beer, come back in a while. 
If he's got more than two cleared for you, for $10 you're ahead of the 
game...
    Seriously those bolts are TOUGH. Expect 15-25 minutes per, to hacksaw 
out. Hopefully tricks #1 & 2 will be sufficient.

Good luck.

Karl


>From: "Peter" <peter@thescirocco.com>
>Reply-To: peter@thescirocco.com
>To: "'Michael Bueti'" <michaelbuetiwon@gmail.com>
>CC: Scirocco-l@scirocco.org
>Subject: RE: Mk1 transmission removal AGONY!
>Date: Fri, 30 Jun 2006 19:08:27 -0400
>
>Yes, and it's a pain in the a$$!
>
>I'd try a visegrip, to break them loose. Obviously it's a little tedious,
>because usually you can only work on the bottom one, so you'll have to
>rotate, clamp, break loose, rotate, and repeat.
>
>If that doesn't work, I'd cut the heads off the CV bolts, work the axle 
>off,
>and the bolt stubs can usually be turned out by hand.
>
>HTH!
>
>Peter-302.832.8989
>http://thescirocco.com/
>
>Please! Include the previous text in your reply...
>
>-----Original Message-----
>From: Michael Bueti [mailto:michaelbuetiwon@gmail.com]
>Sent: Friday, June 30, 2006 6:24 PM
>To: scirocco-l@scirocco.org
>Subject: Mk1 transmission removal AGONY!
>
>It has been a while since I've removed one, but I don't ever remember it
>being this annoying. I mean ACK!!
>
>Problem now is the driveshafts. I cannot seem to get the bolts out no 
>matter
>what. I am w/o airtools and the 12 pt allen socket I have keeps wanting to
>round. I'm tapping the bolts with a hammer. I think I'm gonna drop the
>transmission with the driveshafts attached.
>
>Has anyone ever dropped the trans with the driveshafts attached?
>
>
>
>--
>Michael Bee and Butch > a lethal combination.
>
>1980 Scirocco 1.8 8v 4spd
>1990 Audi 200TQ Avant 10v 5spd
>1993 Chevrolet K1500 Z71 "VW tow truck"
>
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