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Topic: Converting from an Autostick to a Manuel  (Read 17487 times)

Offline nanabug

  • Joined: Nov 2007
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Converting from an Autostick to a Manuel

« on: November 03, 2007, 02:02:43 PM »
Hello.

I have recently gotten a 1971 Volkswagen Super-Beetle with an Autostick transmission.  The car looks great, but the transmission is a little odd.  I have read that the Autostick Transmission wasn't the greatest idea VW has had.  We are having many problems.  (ex. clutch doesn't kick in, car gets stuck in gear, etc.)  My father has owned two bugs in the past with manual transmissions and has never had transmission problems like the one we have now.  I understand that autostick bugs are "collecter's items," but I want this car to run well.  Is there a way I can convert the transmission from an Autostick to a standard manual?  

nanabug

Offline Zen

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Converting from an Autostick to a Manuel

« Reply #1 on: November 03, 2007, 05:21:14 PM »
Provided there is a factory installed clutch cable tube in the tunnel, it's a pretty straight-forward, exchange.  Just unbolt and remove the auto-stick stuff and replace it with manual stuff.  I may miss a few things, but here are the main changes.

Remove the engine and tranny.  Replace the engine's oil pump with a regular pump (the auto-stick uses a special pump . . . pumps oil in the engine and tranny fluid on the outside).  Remove the flex plate and replace it with a flywheel (change your main oil seal and set your end play while you're there).

Remove the vacuum canister from under the left rear fender and the transmission fluid reservior from under the right rear fender.  Remove the vacuum control valve from the rear firewall.  Remove the shifter and the shift rod.  Remove the pedals.

Put it back together with manual transmission pedals, shifter, shift rod, a manual tranny, and your "manualized" engine.

SAVE ALL THE AUTOSTICK STUFF!!!  There aren't too many of them around anymore and someone will need something you have to keep theirs on the road.

IF you don't have a factory installed clutch cable tube and the autostick is working . . . don't mess with it.  :wink:  To install a tube, you have to cut the tunnel open in three places, install and tack in the tube, and weld the tunnel back up.  It's not an impossible job, but you have to know what you're doing and be a pretty good metal fabricator or you might end up with a real hack job.

From what I've been told, prior to 1972 it's kind'a hit and miss if you have a tube from the factory.  From 1972 on they all had tubes.  Originally the factory had one assembly line dedicated to autostick.  No chassis off this line ever had a clutch tube installed.  But sometimes the autostick chassis line would fall behind production and they would pull manual chassis to catch it up.  In 72, they droped the dedicated autostick chassis line and put tubes in all of them.  I don't know if that's really the way it was, but it's what I've been told and from all of the autosticks and former autosticks I've seen over the years, it seems right.  Ret.Bugtech can probably shed some light on this and straigten me out if I'm way off . . .

Offline nanabug

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Converting from an Autostick to a Manuel

« Reply #2 on: November 04, 2007, 08:38:14 AM »
Thank you very much for your answer.  

Quote
Put it back together with manual transmission pedals, shifter, shift rod, a manual tranny, and your "manualized" engine.


When you say "manualized engine" do you mean a fully replaced engine, or just the engine that we made changes to?  (Removing the vacuum canister, flexplate, etc.)  I wanted to keep the engine if possible.  Are there special engines for manuel and autostick transmissions?

Quote
From what I've been told, prior to 1972 it's kind'a hit and miss if you have a tube from the factory. From 1972 on they all had tubes.


That is sad to hear.  But I'll check later today.  Hopefully we have one.  We don't want to mess with the tunnel too much.  But we'll see what we can do.

Thanks again for your reply.  

nanabug

Offline Zen

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Converting from an Autostick to a Manuel

« Reply #3 on: November 04, 2007, 06:41:58 PM »
By "manualized" I meant that while you have it out, you need to change out the autostick oil pump for a regular one and remove the flex plate and bolt on a flywheel.  Other than that, the engines are the same.

Offline Ret.Bugtech

Converting from an Autostick to a Manuel

« Reply #4 on: November 06, 2007, 10:54:16 AM »
I have found clutch tubes in '69,70, 71 Auto-Sticks also.
    You can tell if you have a tube or not by looking under the back seat and removing the cover (1 screw) on the tunnel. The tube will be lurking right under the drivers side(left) of the hole next to the accel. tube. Its about 1/2" in dia. Don't confuse it with the emer. brake cable tube  or you can crawl under the car and follow the accel cable to the body. The clutch tube will be right beside the thottle cable tube and may have a rubber plug in the end of it.
     Is your tranny making noise like bad bearings,whining,growling when going down the road or is it just a shifting problem ?    First thing to check is the gear lube level.  Your tranny uses 80-90 w  in the the transmission section . You check it just like a 4 manual box(plug on the side of tranny)
     ATF is used in the torque converter ONLY.  A lot of people thought the ATF took care of the whole tranny. Not so. Nobody ever checked the gear lube and burned up the gear section when it ran out of 80-90 due to leaks etc.  The next thing to check is the set of points in the shift lever itselve. You can lift the rubber up and look for the one wire that comes out of the lever. This controls the shift servo on the tranny and releases the clutch so you can change gears. This wire broke a lot and people just jammed it in gear and later wondered why the tranny broke.
        There are serveral other adjustments that can be made including a clutch adj. belive it or not. Every hose and wiring has to be perfect.
         These trannys were not that bad if folks had serviced them like they were suppose to. Your tranny may just need a little TLC or it might be to late, but I don't know. I'm not there. Parts are very hard to find now and are expensive when you do find them.

Offline nanabug

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Converting from an Autostick to a Manuel

« Reply #5 on: November 11, 2007, 03:22:18 PM »
Thank you for all your information. I looked and only found just two tubes, assuming one is the accelerator cable and the other the emergency break cable. One is larger than the other.

The bug was given to me by my grandmother. It is a 71 superbeetle that has been very well maintenanced. While searching for the clutch cable tubing I noticed an extreem amount of, which appears to be, grease underneath the right rear section of the bottom. I'm assuming it has something to do with the transmission. Even though the transmission really does work quite well, it only occasionally sticks in gear. My quick remody for that, especially at a red light, is turning off the engine, popping the gear into neutral, and then turning the car back on. It works just fine after that. It works pretty good for being close to 37 years old and wanted a more reliable transmission. I know that the manuals don't have as many problems. Plus they are fun to drive.

Offline Ret.Bugtech

Converting from an Autostick to a Manuel

« Reply #6 on: November 12, 2007, 08:23:22 AM »
If the larger tube was right beside the accel. tube, That would be a clutch cable tube. The emer. brakes tubes are down on what we would call the frame horns, close to the rear axles that the tranny is sitting on . One on each "horn" (2) with a hefty cable going to each rear wheel.
     You didn't state if the tranny was noisey or if you checked the fluid levels. These transmission were known for their leaks.  
     I don't think you have a lot wrong from what you are telling me but I'm not there.

Offline nanabug

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Converting from an Autostick to a Manuel

« Reply #7 on: November 12, 2007, 08:39:18 PM »
Sir,

Thanks for the help. The transmission is not noisy. My dad has kept a good eye on the gear oil level and ATF. To be honest it has worked for my grandmother for 36 years. It only has 125,000 miles on it. Garage kept in Chattanooga TN. My Dad just recently drove it up here to St Louis from Chattanooga with no problems. It runs great at 60-65 mph. He drives it back and forth to work because it's great on gas. I'm hoping to find a good VW Bug mechanic around here to swap out the trans. I turn 16 in December and I hope my dad will pass it down.

Offline Ret.Bugtech

Converting from an Autostick to a Manuel

« Reply #8 on: November 12, 2007, 10:52:46 PM »
Well, If everything is going find I wouldn't do a thing to the car until the tranny falls apart or somthing else happens. The car is worth alot more in original condition.  Good luck

Offline Zen

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Converting from an Autostick to a Manuel

« Reply #9 on: November 14, 2007, 07:48:53 PM »
Quote from: "Ret.Bugtech"
The car is worth alot more in original condition.


In more ways than one!  Don't mess with a good thing!  You WILL regret pulling a working autostick the first time you are stuck in a traffic jam on the interstate.  I spent 2 hours going 13 miles on I-285 in a 75 Super Beetle convertible a few years ago . . . my left leg hurt for three days!

Once you learn how to get along with it, an autostick is a BLAST to drive!

If the tranny is shot and you have a clutch tube, going to manual is a pretty smart alternitive to fixing the autostick . . . but if the autostick is working, just take care of it and drive it.   8)

Offline Bugnut

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Converting from an Autostick to a Manuel

« Reply #10 on: November 14, 2007, 10:36:36 PM »
A month ago I begged someone to come get an Auto stick with a crushed top. Wished I would have know. It had everything on it. Now it's a trike. :cry:

Offline Ret.Bugtech

Converting from an Autostick to a Manuel

« Reply #11 on: November 15, 2007, 09:11:27 AM »
I wonder why it is that the older and "crapped" out you get, Automatic anything is wonderful.   Thank God for "remotes". I use to get tickled watching my "elders" flound around.  It ain't so funny now.  Gezz !! I asked a Uncle of a friend of mine how things were going in the bedroom now that he was in his 80's. He told me that it was like shooting pool with a rope :(

Offline Bigdummy

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Converting from an Autostick to a Manuel

« Reply #12 on: November 15, 2007, 09:57:56 AM »
:lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:  :lol:   With a rope!

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