1966 Volkswagen Fastback Eng CD AD, Automatic TransFACTORY OEM SERVICE PROCEDURE

Charging Systems: Generators: Overhaul: Disassembly

  1. Remove fan pulley and spacer washers (Type I & II). Remove fan nut with special wrench (VW I 12 or equivalent) and take off fan with spacers, hub and woodruff key. The fan should be held in position by a second mechanic.
  2. Remove fan cover and reinforcement flange (Type I & II). Remove regulator (if mounted on generator).
  3. Disconnect field coil terminal from brush holder of the positive brush. Unscrew the two housing screws. Lift brushes and take off commutator end plate. Remove ball bearing spring ring.
  4. Withdraw fan end plate and armature as a unit from the housing.
  5. Press the ball bearing, splash shields and spacer ring off armature with a suitable press (VW 400) and suitable press adapters (VW 401, 408 - 6V units, 409, 439 & 686).
  6. Remove end plate at the fan end (Types I & II) with suitable press and adapters (VW 402, 408a & 686).
  7. Remove ball bearing oil slinger from armature and take spacer ring out of end plate. The two circlips can be left on the armature shaft.
  8. If necessary, remove field coils with special pressure type screw remover.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.