Intermediate Shaft Flange is it needed

[ORCoaster]

My son and I are venturing on an adventure keeping a 1980 Dasher alive and kicking.  My question is this:  If the flange on the edge of the intermediate shaft that rubs against the engine block is broken off what is the danger of running it that way?

My son tried swapping the 1.5 shaft he had with the 1.6 but the cut is different on the 1.6 and the rotation is only about 40 degrees of arc before the whole thing comes to a halt.  Works in both directions that way.  He assessed the situation and decided to just let the oil seals do their work and not worry about it.  The engine runs well after a rebuild but we are just questioning the need to pull the engine again and swap the shaft with one that does all the right things. 

Might need to post a WTB ad here.   

[theman53]

I bought an 84 rabbit that was that way for who knows how long, I drove it thousands of miles. I did a timing belt and the IM shaft slipped out while I pulled the old belt out. I would guess that someone pried a little too hard on the IM sprocket and ripped the thing off. Back then was before I was on here and I figured it made it that far who am I to rain on its parade now, so I ran it. Since then being a mod now and having a different luck going on and having a spare shaft I would replace it. As long as it doesn't come out and not pump oil or derail the timing belt there will be no issues from my experience.

[vanbcguy]

They did away with the flange on the later engines, it is fine without it.

[fatmobile]

He's referring to the thrust surface on the actual shaft, not the pully edge.
 You can press the 1.6 gear off and put it on the 1.5 shaft.
 Probably heat the gear and cool the shaft to put it on.
 I wouldn't drive without a thrust surface on the shaft

[JDiesel]

Plus you get no vacuum boost to the brakes?

[CODE4LS1]

I had an '84 Rabbit that I bought like that.  It caused a nasty oil leak.  I found a replacement IM shaft at the junkyard.  Technically should be fine, so long as nothing else goes wrong, but I wouldn't chance it, IMO.

[TimpanogosSlim]

When i disassembled my block i found the flange on my IM shaft cracked, so i bought a new one one from someone on one of the forums.

Technically you could use a gasser IM shaft, but you would have to swap the diesel gear onto the end since the diesel im shaft turns the other direction. Nothing you shouldn't be able to pull off with the right press and a blowtorch.

[ORCoaster]

Well I will let the son know what has been said here.  He was calling tonight to ask about keeping the 1.5 block, although it needs boring and new pistons to make it work.  I think that and the head are destined for the recycle yard.  Most of the smaller parts, and perhaps the cam and crank will be saved but the heavy items are for sure headed to a magnet in the sky.

Anyone need a 1.5 liter block? 

[theman53]

I would donate it to Jetmugg, as a backup for the land speed record if it is viable.

[ORCoaster]

My son said the cylinders were egg shaped according to the measures that he took.  That was a boring expense I didn't want to make so I sent him my spare 1.6.  He thinks the head needs work as it is pressurizing the coolant now.

He also said it had 225,000 miles on the odometer so not sure it is a candidate for a speed record.  Could be wrong.