Case Splitter, for Aircooled VW Engines

OVERVIEW

When you are staring down the barrel of a full engine tear-down, the most nerve-wracking moment is often splitting the case halves. Over decades of heat cycles and the use of heavy-duty case sealants, those two halves become practically fused together. Many novice builders make the catastrophic mistake of using a flathead screwdriver or a pry bar to force the case open, which invariably leads to gouging the soft magnesium or aluminum mating surfaces. Once those surfaces are marred, you are looking at a permanent oil leak or an expensive trip to the machine shop for line boring and deck surfacing. This EMPI Case Splitter is the professional mechanic''s secret weapon to avoid that nightmare, providing a controlled, mechanical force that separates the halves without damaging the precision-machined edges.

Designed to fit perfectly into the oil pump bore, this tool utilizes the strongest part of the case to leverage the halves apart safely. By threading the center bolt, you apply even, gradual pressure that overcomes the suction of the sealant and the friction of the alignment dowel pins. It is a compact yet essential addition to any air-cooled enthusiast''s toolbox, whether you are building a stock 1600cc daily driver or a high-performance stroker race motor. Using the right tool for the job doesn''t just save time; it protects your investment in your vintage Volkswagen engine. Don''t risk a rare AS41 or AS21 dual-relief case by "winging it" with a hammer; use the tool designed specifically for the task and ensure your case remains in rebuildable condition for years to come.

FITMENT

This tool is compatible with the following Air-cooled VW Engines (Type 1, 2, and 3): Volkswagen Beetle: 1950 through 1979 (Standard and Super Beetle) Volkswagen Karmann Ghia: 1956 through 1974 Volkswagen Bus / Type 2: 1950 through 1971 (1200cc, 1500cc, and 1600cc upright engines) Volkswagen Type 3 (Squareback, Fastback, Notchback): 1961 through 1973 Volkswagen Thing / Type 181: 1973 through 1974 Dune Buggies, Sand Rails, and Trikes utilizing VW Type 1 based engine cases

SPECS

• Manufacturer: EMPI
• Part Number: 16-9601-0
• Material: Heavy-duty forged carbon steel for maximum rigidity
• Finish: Black oxide or zinc plated for superior rust and corrosion resistance
• Mechanism: High-tensile threaded pressure bolt with hex head
• Installation Point: Fits standard oil pump bore diameters
• Weight: Approximately 0.44 lbs
• Function: Expands case halves from the inside out to prevent exterior prying

PRO TIPS

Tip 1: The "Hidden Nut" Double Check

Before you even think about tightening the Case Splitter, go around the engine case one more time to ensure every single nut and washer has been removed. It is incredibly common to miss the small 13mm nuts located behind the flywheel or the ones tucked near the cam gear area. If you attempt to split the case with even one nut still attached, the mechanical advantage of this tool is strong enough to crack the case webbing or the oil pump bore. Always verify that the case is truly ready to move before applying pressure.

Tip 2: Use Controlled Heat for Stubborn Sealant

If you find that the tool is becoming very difficult to turn and the case isn''t budging, the old-school sealant (like Permatex Aviation or Curil-T) might be acting like glue. Use a heat gun to gently warm the perimeter of the case mating surface. This softens the sealant and allows the Case Splitter to do its job with much less effort. Never use a torch with an open flame, as magnesium is flammable and excessive heat can warp the case; a standard industrial heat gun is the safest and most effective method.

Tip 3: The "Tension and Tap" Method

For the smoothest separation, don''t try to force the case open all at once with the tool alone. Tighten the Case Splitter bolt until you feel significant resistance, then take a rubber mallet or a plastic dead-blow hammer and give the case halves a few light taps around the perimeter and near the dowel pin locations. This vibration helps break the "stiction" of the sealant and the dowel pins. Alternate between adding a half-turn to the tool and tapping the case until the halves begin to visibly separate. This ensures the case moves evenly and doesn''t bind on the long head studs.