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Date:         Sat, 20 Mar 2010 11:35:28 -0800
Reply-To:     neil n <musomuso@GMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         neil n <musomuso@GMAIL.COM>
Subject:      Re: Trans. Install: Input shaft & clutch splines
Comments: To: Scott Daniel - Turbovans <scottdaniel@turbovans.com>
In-Reply-To:  <139501cac861$31fd0990$6401a8c0@PROSPERITY>
Content-Type: text/plain; charset=ISO-8859-1

On 3/20/10, Scott Daniel - Turbovans <scottdaniel@turbovans.com> wrote:

> It's not together yet ?

Heh. Almost.

Swap was driving fine, but removed "original" DK as it has a funny noise coasting in 1st/2nd at low speed. DK currently being installed is one I bought used. Am hoping it's ok. If so, I may attempt a rebuild of noisy DK. Ha!

> one, if using diesel vanagon flywheel on an inline four engine in a vanagon > with DK trans or input shaft .. > the DK shaft has to be shortened about 12mm from stock.......

Thanks. For sure. I did this at time of swap. Dremel worked for me. :)

I'm sure you know this, but for others, I recently learned that the DV pilot bearing is a sealed unit. I installed a slightly longer (Fox?) PB thinking it might be a sealed unit. (no felt ring required?) Doesn't look like the DV PB I just bought. It has a seal. Still, Fox one still looks fine after ~ 13K Km's. Next clutch, I'll install the DV PB.

> > Always put the trans in any gear, and put the parking brake on ... > so as you are conencting engine and trans you can rotate the crank pulley a > little bit to line up splines.

Good tip. Yup. Did that

> > I have seen where after a lot of horsing around and not getting the splines > to engage ....the splines of the clutch disc got damaged a little....so they > could never engage. Solution was to pull engine and trans back apart, repair > those splines with a tiny file. So make sure that doesn't happen.

Good to know. Same as cleaning up splines on end of a damaged half shaft I bet. (BTDT)

I guess my question should have been simpler.

Like:

If splines UNdamaged prior to tranny R&R, is it possible for "new" tranny to fully mate to engine if splines misaligned?

From what you've said, seems not.

> and you kinda gotta have a plastic dummy input shaft ( comes with a clutch > kit, I have several left over ones I'd sell ) > or a real input shaft for a clutch alignement tool. > If you just try to eyeball it ...you can ... > but that's tricky. > If I had just eye-balled the centering of the disc in the pressure > plate/flywheel , I'd be extra careful about forcing it. > > You probably have it together by now anyway I bet !

Clutch was already installed/working right. This conversion was driving fine.

Tranny is now mated to engine. Just needs buttoning up.

Thanks,

Neil.

> > ----- Original Message ----- > From: "neil n" <musomuso@GMAIL.COM> > To: <vanagon@GERRY.VANAGON.COM> > Sent: Saturday, March 20, 2010 11:58 AM > Subject: Re: Trans. Install: Input shaft & clutch splines > > >> Thanks Dylan. >> >> Clutch was already installed and aligned/working right. For sure. >> Clutch tool is handy. :) >> >> So it's possible to get engine in with splines misaligned? >> >> Didn't feel like I forced engine in, but I used nuts to pull tranny to >> engine (each a bit by bit carefully, engine moved easily though) so >> needed to ask. Last time IIRC, tranny eventually went in "by hand". >> >> Neil. >> >> On 3/20/10, dylan <insyncro@yahoo.com> wrote: >>> forcing it will do damage to the splines. >>> not recommended. >>> get a clutch alignment tool. >>> they are given with complete clutch kits. >>> makes the job very simple. >>> >>> dylan >>> >>> >>> >>> >>> ________________________________ >>> From: neil n <musomuso@GMAIL.COM> >>> To: vanagon@GERRY.VANAGON.COM >>> Sent: Sat, March 20, 2010 2:52:08 AM >>> Subject: Trans. Install: Input shaft & clutch splines >>> >>> Hi all. >>> >>> When installing the transmission, is it obvious if input shaft/clutch >>> splines aren't lining up? Is it possible the transmission can be >>> "forced" in even if splines misaligned? >>> >>> I'm not totally unfamiliar with VW transaxle remove/install, but >>> tonight, it was a royal PAIN. (don't ask) Anyhow, when things finally >>> lined up, and enough thread was showing on lower studs, I used lower >>> nuts, then uppers, to bring the transmission and engine together. It >>> all "felt" ok while doing this, but because I had to use the nuts, I'm >>> asking the above. FWIW, I did jockey the crank back/forth to help make >>> sure splines lined up. >>> >>> ** For others running an I4 with carrier ~ in middle of block, with >>> transmission removed, engine might tilt toward rear of vehicle. MIne >>> did. Jacking up pulley end of engine to normal position obviously >>> helps to line up studs. Before I did this, the rear portion of the >>> transmission was hanging up on cross member, barely allowing lower >>> studs to pass through clutch housing holes. >>> >>> Oh and if you're using a KEP, be mindful of that longer stud. Not sure >>> if all KEP/VW use this, but mine does. >>> >>> Thanks! >>> >>> Neil. >>> >>> -- >>> Neil Nicholson '81 VanaJetta 2.0 "Jaco" >>> >>> http://tubaneil.googlepages.com/ >>> >>> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines >>> >> >> >> -- >> Neil Nicholson '81 VanaJetta 2.0 "Jaco" >> >> http://tubaneil.googlepages.com/ >> >> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines >> > >

-- Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines


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