Tornado red Golf country light restoration

[hessu]

Hi,

Let’s start own thread so no need to hassle under any other ones threads. I bought this -91 Tornado red Golf country Syncro few months ago, 2 previous owners, first one owned card 4 years, next one almost 26 years. Going to do mechanical as well as interior/exterior refurbishment. The car has driven a reasonable 301,000km, externally the car is an incredibly good body. According to previous owner RWD has stopped working 10 years ago and they didn’t find root cause so they removed prop shaft and used car as an FWD only. Before dissaembling car, I try to troubleshoot if 4wd really works or not.

brgrds
Hessu from Finland

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[hessu]

Some parts taken off, sunburn waxed away…..

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[hessu]

Prop shaft CV joints opened, cleaned, degreased and reassembled. Shaft painted. Front/rear support bearings repaired using Tedgum inserts and bearings, prop shaft installed back to car.

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[hessu]

It looks like I can’t add video clips so this question third time, now without video attachement.

I need you syncro know-how and advices what might be a root cause. When driving forward, RWD is not working, when car is off the ground rear wheels are not rotating, when shifting Reverse gear, RWD also works as well as reverse light indicating reverse switch is at least ok? Wonder what to check next?

[LD50]

hiya, wow – nice project 😀 that’s gonna be a *pretty* country when it’s done 🙂

re posting video – that’ll be a question of disk space I would imagine more than video not being allowed – I think it would just have to be under 10mb. we already store a lot of pics and in the budget of £0 there isn’t really the room to handle video as well. However I just did a test and I think you can embed youtube videos which can be super high quality and they have LOTS of storage :). I just posted one of my bike videos into a thread here to test:

https://forum.vwsyncro.co.uk/forums/topic/testing-youtube-video-embed/

On youtube I click the “share” icon, then “embed” and it makes some code like [iframe stuff blah blah] which you copy in and hopefully it should work.

• This reply was modified 4 years, 2 months ago by LD50.
• This reply was modified 4 years, 2 months ago by LD50. Reason: old fingers
• This reply was modified 4 years, 2 months ago by LD50.

My website | My Youtube channel (both mostly bike related)

[hessu]

Hi LD50,

And thanks for the reply and instructions to add Youtube video link. In fact haven’t posted newer ever singly video clips to Youtube so a bit unsure if I use this or not, but

Do you have any idea what might be a root cause for 4WD problem described, read from internet there is some “free clutch” in this system, is it located at the read axel or? Could it be somehow broken, do you or other folks know any procedure how to thest this free cluctch?

tnx
Hessu

[hessu]

Today I checked vacuum lines and didn’t saw any damages or possible places leaking so I removed reverse switch from gearbox to check it, switch type seems to be 191919823D and it has 36 90 marking which I assume is week 36 year 1990 meaning switch is original one? Can I test if this switch is fully ok by using multimeter, any instructions available?

tnx
Hessu

[Chris S]

Testing the Syncro system

Testing the Syncro system

[hessu]

Hi Chris,

Thank you so much, will follow this procedure to check system. Also trying to find pinout or diagram about the 191919823D switch to test is using multimeter.

By the way, there is 2 wires going into rear end axis, do you know what those are for or controlling about?

-Hessu

[hessu]

Followed Syncro testing procedure earlier today and eh, nothing succeeded:

1. This was ok and like this . Spin rear wheels by hand, in forward direction..the rear wheels must spin easily, without resistance, and the driveshaft must not rotate

2. This …spin rear wheels by hand, in rearward direction, the front wheels must be driven in a rearward direction, by the driveshaft. Result was…front wheels didn’t move anywhere

3. let engine run for at least 30 seconds to allow vacuum to build up
– raise vehicle on hoist DONE
– switch ignition ON DONE
– engage reverse gear DONE
– depress clutch DONE
– turn rear wheels by hand, both forward (see Note), and backward DONE
Result: Didn’t hear any “click” from differential lock, front wheels didn’t move at all.

Pneumatic lines checked, can’t find any defects or leaks but not able to recognize where magnetic swithch is located, this switch should click also, is it nearby engine intake manifold or nearby vacuum reservoir at the left front corner of car?

Checked those 2 wires which controls read diff solenoid, no power ever, not in first gear, reverse gear nor neutral?

Located Relay 83 which according to Internet is control unit for rear diff lock, looks like a original relay cause labeled as 12.07.90, condition looks to be ok, removed relay cover, does look also ok inside, need to check if power is coming to relay wires AND check if relay works when 12V is directly given to it.

Checked also 191919823D switch using multimeter, by pressing metal pins I can find it always connect 2 different pinouts together as if I understood correctly, should work like this?

Do you know if there could ever be mechanical problem in those metal tabs pressing 191919823D switch mechanically when changing gears and neutral or reverse gearbox? I mean switch itself could work but there is problem with mechanical connection between switch vs gear shifter?

Tnx

[Chris S]

The magnetic switch is actually located on the rear diff,

2. This …spin rear wheels by hand, in rearward direction, the front wheels must be driven in a rearward direction, by the driveshaft. Result was…front wheels didn’t move anywhere

This sounds like your VC unit has packed up, that is apart from any other possible faults/problems

lloydy may have a spare VC that he might sell?

I will find the rear axle drawings (on here somewhere) & post them

[hessu]

Chris, tnx for replying again.

OUTS, that would be very bad news if VC is broken, it’s too rare to find used VC in working condition here but I haven’t give in with it yet. Can it effect anyhow if freewheel lock solenoid valve is broken?

All wires between reverse switch vs freewheel control unit vs solenoid are checked and are ok.

I took resverse switch out and open, I will check and clean it today, it looks a bit tricky so need to be careful. I took freewheel solenoid valve out from car as well, it looks like there is broken pin in solenoid, could anyone who knows this system verify photo below, from internet I can see there should be round fitting at the end of “brown” plastic pin which is connected then to freewheel moving mechanism, pin head looks to be broken long ago. If this is the case, I’m willing to buy this pin if anyone owns and willing to sell?

tnx
Hessu

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[Chris S]

https://volkswagen.7zap.com/en/rdw/golf+var-syn+rall+coun/gosy/1989-67/5/525-106040/#18

this link shows what you should have in the rear diff

Again I would suggest you contacet lloydy as he may be able to help out

[hessu]

Thanks Chris I will try to email to him right away. PS: very useful link to me you add to previous reply

[Chris S]

Here is the full link

https://volkswagen.7zap.com/en/rdw/

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