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Bakelite fuel pump spacer broke in half
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rks
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PostPosted: Wed May 15, 2024 7:09 am    Post subject: Bakelite fuel pump spacer broke in half Reply with quote

Hello all, working on a 1968 standard beetle, 68,000 original miles, true barn find.
Replaced fuel pump with temporary repop, sending O.E. pump into Sparkwerks to be rebuilt.
During fuel pump removal, following Bentley manual, fuel pump push rod came out but bakelite spacer was varnished tight. Needles to say, with a gentle tap and pry the fuel pump spacer flange came out, unfortunately only 2/3 of the bake lite unit came out.
Question: I was able to replace appropriate gaskets slid top 2/3 of bakelite spacer back in, replaced pushrod, greased cavity in new fuel pump and bolted it up. Fired the ignition and the Beetle came to life. My concern is there an issue running the broken bakelite spacer flange? Pushrod moved up and down when turning engine by hand and the original 1500 runs well.
Thanks for all the experience and wisdom in advance. TheSamba forum for this bug and my 1966 bus are the best!
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Glenn Premium Member
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PostPosted: Wed May 15, 2024 7:38 am    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

You need to replace the entire pedestal.

Use an ez-out to remove the bottom piece.
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rks
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PostPosted: Wed May 15, 2024 7:32 pm    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

Thanks Glenn, will get the bakelite piece extracted. Will the pedestal begin to disintegrate?
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66foot Premium Member
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PostPosted: Wed May 15, 2024 11:45 pm    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

RKS - I agree with Glenn. Get that remaining 1/3 of the old intermediate flange removed.
Here is an old link that might be helpful. I used the lag bolt "extractor tool". It worked pretty good. Slow and steady.
Also, be sure to keep all of your pieces, so you are sure that you removed the entire flange. Or, at least you will know how many "little" pieces are left in the engine block.

https://www.thesamba.com/vw/forum/viewtopic.php?p=2060245
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bnam
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PostPosted: Thu May 16, 2024 5:22 am    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

rks wrote:
Hello all, working on a 1968 standard beetle, 68,000 original miles, true barn find.
Replaced fuel pump with temporary repop, sending O.E. pump into Sparkwerks to be rebuilt.
During fuel pump removal, following Bentley manual, fuel pump push rod came out but bakelite spacer was varnished tight. Needles to say, with a gentle tap and pry the fuel pump spacer flange came out, unfortunately only 2/3 of the bake lite unit came out.
Question: I was able to replace appropriate gaskets slid top 2/3 of bakelite spacer back in, replaced pushrod, greased cavity in new fuel pump and bolted it up. Fired the ignition and the Beetle came to life. My concern is there an issue running the broken bakelite spacer flange? Pushrod moved up and down when turning engine by hand and the original 1500 runs well.
Thanks for all the experience and wisdom in advance. TheSamba forum for this bug and my 1966 bus are the best!


You'll be ok running with the broken spacer for a little bit. I ran my car this way for several 1000kms. But change it properly when you install the rebuilt pump.
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rks
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PostPosted: Thu May 16, 2024 8:02 am    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

Thank you 66foot, awaiting the new intermediate flange from WW.
Headed back north from the family homestead in Wyoming and will be trailering the beetle, hopefully it'll be ok to start the engine and drive up on the trailer for transport?
Once back in BC I'll extract the bottom the bottom third.

bnam, appreciate the encouragement, thanks.
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airschooled
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PostPosted: Fri May 17, 2024 8:38 am    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

I drove across the US three times with a broken flange. You’ll be fine.

Robbie
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NJ John
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PostPosted: Fri May 17, 2024 11:40 am    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

I put a rod with a hook like bent over tip into a slap hammer. It worked well.
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Craigbro
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PostPosted: Thu May 30, 2024 7:01 pm    Post subject: Re: Bakelite fuel pump spacer broke in half Reply with quote

Just pulled my pump today and lifted out the spacer and likewise only the top 2/3 came out.
After reading through threads on the subject I first tried the easy-out without success so resorted to a 3/8 - 16 tap to cut threads into the stuck plastic piece and then threaded in a long bolt with a fender washer and nut, screwed down the nut which slowly lifted the stuck piece right out.
Found several You Tube videos on this as well.
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