Beetle Repairs

Our 1975 Volkswagen Beetle has been with Jonn undergoing several repairs and adjustments:

• A new heat exchange control lever knob was installed between the seats.
• A new brake reservoir cap was fitted.
• A new engine compartment lock was installed and tested.
• A new nearside door pin switch was fitted. The wire was crimped with a new terminal, connected, and tested for functionality. The interior light operated correctly via the door switch.

The nearside window regulator was replaced. The replacement part differed slightly from the original, requiring modifications:

• The lower edge of the original regulator was cut off, drilled, and bolted to the new regulator to secure it to the bottom of the door.
• The bolt holes in the door were aligned.
• A runner was drilled and riveted to prevent the window from lowering excessively.
• Testing revealed that the top window rubber was not fully seated, preventing the window from rising sufficiently. Adjustments were made by modifying the regulator where it attaches to the window. The glass was drilled out, raised to align with the newly adjusted regulator holes, secured, and tested. The window now operates correctly, though the regulator slips slightly if forced too high. Grease was applied to the regulator to improve movement, and the window was confirmed to go up and down smoothly. The door panel was refitted and retested successfully.

The vehicle was then raised on a ramp, and the wheels were removed to inspect the brakes. Both front brake cylinders were found to be leaking and require replacement:

• The handbrake was de-adjusted, and the nearside rear brake was adjusted.
• The brake drum was refitted, and the hub nut was torqued to 250 lb/ft.