Steering Coupler

When replacing my horn wire, I noticed a large separation in the connector that goes between the steeting column and the steering box. Looks like it could come apart at any time. The separation looks like a gap left when a thin slice is taken from a pie. The coupler is round and appears to be some kind of rubber material and has four bolts holding the whole assembly together. Checking my maintenance manuals no mention is made of replacing this. It does not seem to be too difficult but I have had that same opinion when starting other projects only to be fooled by something I did not know about. Any secrets about replacing this and any recommendations on where get a replacement and what to order.

Certainly not going to drive the car until this is replaced. I'd hate to have it self destruct at freeway speed or heck any speed for that matter.

You can get the stock rubber flex coupler disc or upgrade to a urethane one from any aftermarket VW supplier for about $6
Drill out the heavy factory rivets and replace them with grade 8 bolts with nyloc nuts
While your there, take a close look at the steering column crush cage
if yours have one, look for small hair line cracks around the weld areas. I had a used one seperate with out any indication of a problem. Luckly it was while loading the speedster on a trailer.

Any tricks other than replacing the rivets? No Crash cage. Seems pretty straight forward. Just unbolt the four bolts take the old one out and just install the new one. I had forgotten how easy VW's were to work on. If I'm real lucky maybe the stupid horn will stop honking.
Troy

Be positive Troy, even if your horn worked perfect, that guy in the big SUV with all his toons blaring out at 99 decibels through his $3000 sound system, his windows rolled up, his air conditioning on full, his drivers and passenger windows illegally tinted to about total blackout, will render your puny horn totally useless anyhow. Just use your evasive capability (evasive capability is aided by a steering shaft coupler that is all in one piece).

Actually I was very close to tossing "The Club" into the guys rear window but he stopped just short. I'm just really happy that I found the defective coupler before it found me.

troy-
if you havent bought a coupler yet- come by and ill give you one. Or im sure you know where beetle power is. Talk to Tony- he has them in stock

Troy,

The common name for the "Coupler" is referred to as a "Rag Joint".

You have a couple of options.

There is a Solid Polyeuthrone replacement or the VW Factory replacement.

If you are Auto Crossing, many choose to utilize the Solid replacement.

If you are merely driveing the car at HWY Crusing Speeds, the steering input will be pretty "Harsh" with the Solid Design. The VW Factory Rubber Coupling absorbs shock along with the Steering Dampner.

The steering dampner is a small "Shock" the is installed parallel the the front Torshion Bar Assembly attaching one end to the steering linkage and the other to the Torshion Bar Assembly.

As for replacing the coupler. Jack the car up and support with Jack stand. Its easier to remove the L/F Wheel after raising the car take I believe a 13MM Box End Wrench and a 13MM Socket/Ratchet.

Two of the bolts connect the Steering Shaft to the Steering Wheel and the other two bolts connect the Steering Box to the coupler.

Pay attention to the position of the Steering Wheel when removing the Coupling fasteners and repeat the procedure.

Thats it.

Good Luck,

Jack

Did it (urethane) and it worked great. The really scary part was just I removed the second bolt the old rubber coupler fell off in two pieces. Guess it was already broken and just the friction of the washers held it together. Scared the %#!* out of me just thinking about what could have happenned. Another item to check occassionally.