Date:         Thu, 13 Nov 2003 20:41:08 -0500
Reply-To:     Dennis Haynes <dhaynes@OPTONLINE.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dennis Haynes <dhaynes@OPTONLINE.NET>
Subject:      Re: flywheel pilot bearing will not fit!
Comments: To: vw4x4@FYI.NET
In-Reply-To:  <3FB3AC81.1050906@fyi.net>
Content-type: text/plain; charset=us-ascii

The pilot bearing is probably an aftermarket one with the seal built in.
Beck Arnley supplies these. You have 3 options. Replace the pilot
bearing with a correct one, Bore out the center of the flywheel, or Use
a dremel or die grinder to remove the shoulder in side the crankshaft. I
prefer option 1 or 2. The main benefit of option #2 is that the felt
seal and the un-available metal sleeve in the flywheel center are no
longer needed.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf
Of Eric Zeno
Sent: Thursday, November 13, 2003 11:09 AM
To: vanagon@GERRY.VANAGON.COM
Subject: flywheel pilot bearing will not fit!

Here is one for the record books.
I'm helping  a friend put in a new
clutch in his 1.9L  / 2.L mixture.
The engine and crank are 1.9L.  We installed
the pilot bearing as far as it would go. This
leaves it sticks out of the crank about 1/16".
When installing the flywheel, the hole in its
center, is not big enough to fit the pilot bearing.
Therefore as you tighten up the flywheel
you crush down the end of the pilot bearing
making it impossible to install the input
shaft of the transmission, without major
force.  This is exactly what the DPO did.
The pilot bear did not last, and then the
clutch went.  Now we have to fix this mess.
Any have any insight?
                                  Eric