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von Kerry Chadderton
Donnerstag 18. Oktober 2018, 13:12
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

bic & tomtom, Thank you for the clarity and details. I searched ebay many times but obviously it helps to know what exactly what you are looking for in terms of part numbers. A new sensor is on the way from Germany! I'm still going to disassemble the old one and try to fix it. I love a challenge...
von Kerry Chadderton
Freitag 12. Oktober 2018, 22:54
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Well I have removed the sensor (encoder) and tested it in a pot of water on the stove. As the temperature increased I began to see liquid oozing from around the plastic cap. There's water inside. This is my fault! I was so happy to have the Wartburg running well that I treated the engine area to a g...
von Kerry Chadderton
Montag 8. Oktober 2018, 13:25
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

tomtom, In the picture is how I received the car, so a previous owner or mechanic has welded the connection. I do not know why. Your information is good and gives me confidence to attempt a repair. It is possible that the connection beneath the weld has corrosion, making a bad contact point. I have ...
von Kerry Chadderton
Freitag 5. Oktober 2018, 15:19
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Tomtom,

Will this do?

20181005_090943_resized.jpg


If this is not good enough I can remove, clean it and take better pictures.
von Kerry Chadderton
Donnerstag 4. Oktober 2018, 22:02
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Once again you have saved me from stress! I performed the 150ohm resistor test and the problem lies in the sensor itself. I am relieved. However temperature sensors are hard to come by here. I am attempting to find a cross-reference part, such as the 40hp VW clutch disc and the 2.8 litre GM thermost...
von Kerry Chadderton
Mittwoch 3. Oktober 2018, 22:23
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Warre, Your logic is sound. I thought of that and replaced the spade connector at the temperature sensor. There was no change in the gauge behavior. Since I have a fault in the LED fuel gauge these all could be signs that the entire gauge assembly is going bad. I can live with a faulty fuel level, o...
von Kerry Chadderton
Dienstag 2. Oktober 2018, 14:39
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Hello again! I hope everyone is well. I've been sidetracked with family obligations and have not had as much time to spend with the Wartburg. The clutch repair was a great success. I have put 240 trouble-free kilometers on it since. There is a new issue. The temperature gauge flickers in and out and...
von Kerry Chadderton
Freitag 21. September 2018, 17:29
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Markus,

Okay. It is good to have that knowledge. I will explore a bit and see if it is something that I can fix.

Have a good weekend. I am looking forward to beer and sausages myself! {beifall}
von Kerry Chadderton
Freitag 21. September 2018, 14:16
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Warre 1000, You were right. The 1st/2nd shift was hitting the reverse lockout in it's travel. A minor adjustment. It shifts perfectly now. Thank you. Markus, Thanks for the link. The description of operation cleared up most of the mysteries. The 3 position switch is working. However the fuel level g...
von Kerry Chadderton
Mittwoch 19. September 2018, 01:06
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

MarkusH, Thank you! I was completely mistaken. It makes sense now. I thought it was the strangest tachometer I had ever seen! I switched the ground wire when reassembling. The schematics you have provided are priceless. I need the wiring diagram to fix the fuel gauge as well. What does the 3 positio...
von Kerry Chadderton
Dienstag 18. September 2018, 01:18
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

The engine is back in and everything works well! I drove 120km over the weekend. It's very reliable and quite a conversation piece. It has some vibration at 100kph but that goes away at 120kph :smile: I will post pictures of the clutch and disc. The VW 180mm "40hp" friction disc had to hav...
von Kerry Chadderton
Dienstag 11. September 2018, 22:31
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Thanks guys! My torque wrench covers all forms of measure so the conversion is not necessary. I agree Warre, sometimes I go by the "experience torque wrench" :lol: The screws that most concern me are the clutch screws. Do you have any help for adjusting the gear shifter (circuit)? I have i...
von Kerry Chadderton
Montag 10. September 2018, 23:59
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

I'll be installing the engine tomorrow. I have a few questions:

What is the clutch pressure plate to flywheel bolt torque?

What are the engine to transmission bolt torque values?

Can you guide me to the proper way to set, or adjust, the shifter (circuit)?

Thanks in advance. -Kerry
von Kerry Chadderton
Freitag 7. September 2018, 22:12
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

I have finished regenerating the pressure plate. It looks good. I just hope it works as well. I chose not to remove all of the scratches on the flywheel as this would needlessly remove a lot of metal. It looks serviceable and the dimensions are right. The friction disc will arrive on Tuesday so I wi...
von Kerry Chadderton
Donnerstag 6. September 2018, 21:53
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

bic, I have the old style clutch and swivel bearing. My first picture is only half the assembly. The pressure plate completely separated! I have carefully disassembled the pressure plate. It is not damaged exactly. After further investigation I have come to the conclusion that this is a poorly refur...
von Kerry Chadderton
Donnerstag 6. September 2018, 19:05
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

I was able to remove the engine with ease. As you can see the three bolts holding the straps in place worked loose. One of these wedged itself under the pressure spring causing uneven and limited clamping force. There is no damage to the transmission shaft and there is no oil in the bell housing. 20...
von Kerry Chadderton
Donnerstag 6. September 2018, 12:53
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

bic,

No, I meant the ignition assembly at the front of the crankshaft. Now I see that the grill assembly must be removed instead. I'm glad that I asked!
von Kerry Chadderton
Mittwoch 5. September 2018, 22:54
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Warre 1000, That disc is ingenious! I could have used this idea many years ago on an old VW. The engine comes out tomorrow. I am anxious to see what is happening there. There are no unusual noises. The clutch operation seems normal. I am not overly afraid. It just has a lack of grip when I apply the...
von Kerry Chadderton
Dienstag 4. September 2018, 23:22
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Today I changed the oil to a high quality EP 80 GL4. I adjusted the clutch to 2.5 cm at the pedal (with the spring detached). The test drive revealed that the freewheel works well but that the clutch is slipping in both positions. I have to replace the clutch friction disc at minimum. Flushing the t...
von Kerry Chadderton
Montag 3. September 2018, 14:46
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

I did not know how to lock/unlock the freewheel before. I did this with the car stopped and engine off. I hope I didn't damage anything. However the lever operation was smooth and positive. I have a good understanding of mechanical operation and did not use too much force. From now on I'll follow th...
von Kerry Chadderton
Sonntag 2. September 2018, 16:21
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

bic, Those pictures help me understand the operation. Maybe my interpretation of the symptoms is what is wrong. I will re-check everything and test drive the car again. Can the freewheel be locked and unlocked while driving, or is it best to come to a stop first? I am not with the car today. I will ...
von Kerry Chadderton
Samstag 1. September 2018, 20:45
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

bic, I changed the gear oil first thing to look for damage, even before driving the first time. I found approximately a 1/2 teaspoon of hard, small metal pieces. I have seen worse so I was not overly concerned. I filled the gearbox with Valvoline Synthetic 75w-90 Gl-5. It is a relatively thin oil wh...
von Kerry Chadderton
Samstag 1. September 2018, 18:15
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Warre 1000, It sounds as if I might be wrong in my diagnosis of the clutch then? When the freewheel is unlocked the operation of the freewheel seems to disconnect and reconnect with the throttle on and off as it should. The operation is nice and smooth. However, when accelerating more than 1/2 throt...
von Kerry Chadderton
Samstag 1. September 2018, 16:28
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

bic, Thank you so much! The problem with the clutch appears to be friction rather than mechanical operation. There is no noise, binding or chattering. I have not removed the clutch as yet. The problem could merely be oil ingress or driver abuse. If so, a good cleaning, truing of surfaces and a new f...
von Kerry Chadderton
Samstag 1. September 2018, 14:06
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Re: Hello from America !

Hello and thanks for responding. As I stated in my introduction the chassis, body, brakes and electrical system are in great shape. The odometer states 39,000 km, which I believe. The owner had taken the carburetor apart to treat a problem that was ignition related. I was able to fix the original pr...
von Kerry Chadderton
Freitag 31. August 2018, 01:13
Forum: Neuvorstellungen
Thema: Hello from America !
Antworten: 59
Zugriffe: 5363

Hello from America !

Hello everyone! I am an independent mechanic who owns a small garage in Easton, MD on the east coast. I specialize mostly on air cooled Porsches and VW's. As a result of this I have a wonderful customer who was born in East Germany. He bought himself a 1985 Wartburg 353W and has tasked me with resto...

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