Aircooled VW Addiction - Defrost Tube Replacement

GregM writes "Replacing the front defrost tubes is a pain to do. I have done it and would like to tell you how. This is not a quick job. The easiest way to get to them is to remove the stuff that hides them. Start with the hood. Remove it, hinges and all. Simply remove the 13 MM bolt that attaches the hinge to the body. There is one on each side. You don’t have to worry about alignment when you re-install it. Take the springs loose from the trunk bottom first. A helper is a must.

The tubes can be bought at www.wolfsburgwest.com. If you want to buy them local, I got a set at Auto Zone. They are a preheater hose that goes to the air cleaner. The product number is a Dorman 708-002. It is a 1 3/4” in diameter by 18”. It is an aluminum hose that is compressed and can be stretched.

With the hood removed, carefully remove all three defrost tubes from their final destination.. Bend up the wire tang that holds them flat against the trunk floor. It is important to put them back under the wire because the hood hinge will cut them up if they are not flat against the floor.

Remove the defrost tube from the heater channel keeping the three other hoses in place. Study their position or take a picture if need be. They MUST go back in the same position.

Next clean up the debris off of the heater channel. Use a flat tipped screw driver to pries and scrape the remaining hose off of the flange. There is a tiny inspection hole inside the car in the bottom of the kick panel. You will have to pull up the carpet to see it. Use a shop vac to vacuum up the trash that has accumulated in area of your heater channel. A magnet on a pole might be of some help, but I found that the shop vac did the trick.

Now you need to prepare your hose. Start by installing the 3-way splitter with the three smaller hoses removed. Take the end that will be attached to the heater channel flange and use a funnel to “Stretch” the end so it is easier to install. Use some high-temp gasket sealer and smear a little around the “Flanged” opening of the hose. If you are on the driver’s side of the car use your right arm; and your left arm for the passengers side of the car. Stand beside the fender facing the center of the hood. Use a good flashlight to look where you are going to install the tube to get a “Visual” of where you are going. You will have to do the actual installation by feel. because you will not be able to see what you are doing. Lower the tube with the splitter installed to the flange on the heater channel. If you think you have put it on, check your progress by looking through the inspection hole. If you have successfully gotten the tube started, reach back down and push it home. Let it sit for an hour or two to let the sealer bond.

Carefully extend the tube to the proper height. Use a twisting motion to keep the tube tight. (Like a Chinese finger puzzle)

Re-attach the smaller hoses starting with the one that is closest to the door post. Adjust the height of the main tube so that there is a good fit. Re-attach the other two hoses, Close up the wire guide, and re-attach the hood. (with your helper’s assistance)

If might help to wear a disposable long sleeved shirt, because there are things that will cut your arm up about half way down."