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On 5 Jun 2004 at 14:47, eggmeg@netzero.net wrote: > I noticed an oil leak last week. Inoticed it wasn't coming from the > drain but from the pump. I took off the back half and got to the pump. > One of the bottom studs was broken off. After opening up the pump and > scraping off a ton of gunk, I found the stud was shaved off flat at > the block. After trying to drill into the stud for two days it > suddenly went through with ease. Well to make a long story short, the > bit slipped off the stud and went through the block, breaking off the > small corner on the outside of the stud. It can be fixed, but I don't think it can be done with the engine together. You can certainly do the repair that way, but you'll be left with a lot of steel and aluminum shavings in the sump of the case. Since you would have to open the case to clean them out, you might as well take it apart now. Yes, it's a lot of trouble. Sorry. > Does anyone have a suggestion as to a) how to remove the rest of the > stud and b) is there a fix for the corner? I'm stuck for ideas and I > don't want to do any more damage. If you mean that you've just broken off some of the light casting material outside the stud, then I wouldn't worry about that. Only the material inside the stud is important for sealing the pump. To fix the problem, I would take everything apart, then file or mill out the remains of the stud. Use the pump body to guide the drill and drill the hole out for a Helicoil (M8 x 1.25.) It sounds like you just found time for a complete engine rebuild. Do you have a good manual? If you don't want to do a rebuild now, you might just look for a good used 6V type 3 engine somewhere nearby and install that while you're thinking about your rebuild. -- ******************************* Jim Adney, jadney@vwtype3.org Madison, Wisconsin, USA ******************************* ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org