Taking Apart The Vw Bug: Body Off The Pan

Removing the body of a VW Bug from its floor pan is a simple process, but it requires a few tools and a bit of know-how. The VW Bug, also known as the VW Beetle, is a beloved car for its cool, cute, economical, and fun qualities. The process of removing the body involves disconnecting the negative battery cable, removing the seats, and pulling the engine. One must also detach the electrical cables from the starter motor, disconnect wires from the oil pressure switch, and remove the air cleaner from the carburetor. It is important to cover the air intake portion of the carburetor to prevent debris from entering. Additionally, the fuel tank must be removed, and the steering shaft must be disconnected from the coupler. Finally, the body can be lifted from the chassis, requiring four individuals to lift while a fifth pushes the chassis clear.

Disconnect all parts holding the body and chassis together

To disconnect the body and chassis of a VW Bug, you will need to remove all the parts that hold them together. This includes the following:

Chassis Mounts

These are the components that attach the body of the car to the chassis. They are usually made of metal and are bolted or welded to both the body and the chassis.

Clamps

Clamps are used to secure the body to the chassis in several places. They are typically made of metal and can be removed with a wrench or socket set.

Bolts

Bolts are used to fasten the body to the chassis. They can be removed with a socket or wrench. Make sure to keep track of the bolts as you remove them, so you can put them back in the correct order when reassembling the car.

Seals

Seals are used to prevent water and dirt from entering the body-chassis joint. They are typically made of rubber or foam and may require a sealant to be removed properly.

Gaskets

Gaskets are used to create a tight seal between the body and chassis, and they help to absorb vibrations. They are typically made of rubber or foam and may require a sealant or adhesive to be removed.

When disconnecting the body and chassis of a VW Bug, it is important to work systematically and keep track of all the parts removed. This will make the reassembly process much easier and ensure that you do not lose any important components.

Prepare sawhorses and a jack to lift the body

Preparing sawhorses and a jack to lift the body of a VW Bug requires careful attention to ensure safety. Here are some detailed instructions to guide you through the process:

Sawhorses

Sawhorses are essential to support the body of the VW Bug when it is lifted off the pan. It is recommended to build standard sawhorses with a cross-member at the bottom to allow for the mounting of wheels. This addition will enable you to move the body around with ease. The height of the sawhorses should be carefully considered: make sure they are tall enough to clear the transmission or engine, but not too tall that they hinder your ability to roll the chassis in and out of the garage.

For added stability, some people choose to build their sawhorses using 2x4s nailed together to form an I-beam structure. This design provides extra strength to support the weight of the Bug's body.

Jack

When it comes to selecting a jack, a two-ton hydraulic jack is generally recommended for lifting a VW Bug. The original VW jack, known as the Bilstein jack, is designed to jack up the car from one side, using the jacking points welded to the longitudinal center of gravity on both sides of the vehicle. However, if you are missing the original jack or the jacking points, as in Dave's case described by John Muir, a 2-ton scissors jack or a hydraulic floor jack can also do the job.

To use the jack safely, it is crucial to identify the correct jacking points on the Bug. Avoid using the jacking points recommended in the Owner's Manual, as these areas are often the first to rust. Instead, focus on the center of the bottom tube of the axle beam for the front of the car and the center of the motor mount carrier for the rear. By placing a piece of wood between the tube/motor mount carrier and the jack, you can safely raise the front/rear of the car.

Additionally, always use jack stands to support the weight of the car when working underneath it. Chock the tires on the end that remains on the ground with concrete blocks for added stability.

Remove the seats, motor, and gearshift

To remove the seats, motor, and gearshift from a VW Bug, follow these steps:

Removing the Seats:

Start by removing the seat bolts using a suitable tool, such as a socket wrench or a ratchet. There will be bolts securing the seat to the floor of the vehicle. Once the bolts are removed, lift the seat out of the car. If the seat is a slider, you may need to remove the slider mechanism as well. This will involve additional bolts that secure the mechanism to the floor.

Removing the Motor:

First, disconnect the battery to avoid any electrical issues. Next, drain the engine oil and coolant to prevent spills. Then, remove the engine bay components that are in the way, such as the radiator, hoses, and fans. Disconnect all the hoses, wires, and cables attached to the engine. This includes the throttle cable, fuel lines, and electrical connectors. Lift the engine out of the vehicle using an engine hoist. Place the engine on a secure stand or surface.

Removing the Gearshift:

• Remove the passenger-side cup holder using a 3mm Allen wrench to detach the screw and washer. Turn the cup holder counterclockwise, unlock it, and wiggle it out.
• Pry out the trim plate around the gearshift using a thin wooden or plastic tool. There are small plastic tabs securing the trim that need to be unlocked.
• Pull out the metal lock piece that is now exposed.
• Put the key in the ignition and move the shifter to a perfectly vertical position.
• Tap, twist, and turn the handle while pulling out the chromed unlock button. It needs to click into a detent position, so keep trying until you achieve this. If the knob is too slippery, use duct tape to improve your grip.
• With the knob in the detent position, secure it with duct tape to prevent it from popping back in.
• Pull the knob up and off the shifter. The chrome piece below it will come off with it.

These steps will allow you to remove the seats, motor, and gearshift from your VW Bug, preparing you for further disassembly or modifications.

Disconnect the fuel tank and steering shaft

Disconnecting the fuel tank and steering shaft is a crucial step in removing the body of a VW Bug from its pan. Here is a detailed guide on how to do it:

Disconnecting the Fuel Tank:

• Before starting, ensure you have the necessary tools and safety equipment, including gloves and eye protection.
• Begin by locating the fuel tank, which is positioned at the front of the vehicle.
• Place a container underneath the fuel tank to catch any spills.
• Identify the fuel lines and hoses connected to the tank. There should be an inlet and an outlet hose.
• Carefully loosen and disconnect the clamps securing the hoses to the tank.
• Gently pull the hoses away from the tank.
• If there is a fuel filter in the line, remove it as well.
• Some models may have additional connections, such as electrical wires or brackets, securing the fuel tank in place. Disconnect these carefully.
• Once all connections are released, carefully lift and remove the fuel tank from the vehicle.

Disconnecting the Steering Shaft:

• The steering shaft is located underneath the steering wheel and connects the wheel to the steering gearbox.
• Before disconnecting the steering shaft, ensure the front wheels of the vehicle are pointed straight ahead.
• Remove the steering wheel by first disconnecting the cable from the negative terminal of the battery.
• Using a knife blade, carefully pry out the center cap of the steering wheel.
• Disconnect the wire leading to the horn switch.
• Locate the large steering wheel nut, typically measuring 27mm, along with the spring washer. Remove these using a ratchet and a suitable socket.
• Using a rocking and pulling motion, pull the steering wheel upward and off the splines. You may need to use the ball of your hand to bump the steering wheel spokes towards you to dislodge it. Avoid hammering on the shaft.
• With the steering wheel removed, you can now access the steering shaft.
• Identify the steering shaft and any components attached to it, such as turn signal levers or wiring.
• Carefully disconnect any wiring or components attached to the steering shaft.
• Loosen and remove any bolts or fasteners securing the steering shaft to the steering gearbox or column.
• Gently pull the steering shaft away from the gearbox or column, being mindful of any surrounding components.
• With the steering shaft disconnected, you can now separate the body of the VW Bug from the pan.

Remember to work carefully and methodically when performing these steps, as they involve critical systems in your vehicle. Always refer to a qualified mechanic or VW specialist if you are unsure about any part of the process.

Lift the body and separate from the chassis

Lifting and separating the body of a VW Bug from its chassis is a straightforward process, but it requires careful attention to ensure it is done correctly. Here is a step-by-step guide to help you through the process:

First, it is important to understand the structure of the VW Bug. The pan of the VW Bug, or Beetle, serves as the "chassis". When bolted together, the body and the pan create a unibody structure. However, they can be separated, and the pan can even roll on its own with some simple wiring modifications.

Next, gather the necessary tools and resources. While VW enthusiasts boast about how few tools are needed to work on these cars, you will still need to ensure you have the right equipment to safely lift and separate the body from the chassis. This may include jacks, stands, and any other tools required to remove the bolts and attachments that hold the body and pan together.

Once you have the necessary tools, you can begin the process of separation. Start by carefully jacking up the VW Bug to gain access to the underside of the vehicle. From here, you will need to identify the bolts and attachments that secure the body to the pan. With these identified, you can begin to remove them, taking care not to damage the body or pan in the process. It is important to work methodically and carefully, ensuring that the body remains stable and secure as you work.

As you remove the bolts and attachments, the body and pan will become separated. Take your time with this process, as rushing may result in damage to either component. Once all the bolts and attachments have been removed, you should be able to carefully lift and separate the body from the chassis. With the body lifted and separated, you can now work on each component individually, whether that involves repairs, modifications, or replacements.

Frequently asked questions