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Date:         Tue, 5 Jan 2016 12:54:32 -1000
Reply-To:     "SDF ( aka ;jim lahey' - Scott )" <scottdaniel@TURBOVANS.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         "SDF ( aka ;jim lahey' - Scott )" <scottdaniel@TURBOVANS.COM>
Organization: Cosmic Reminders
Subject:      Re: Transmission swap problems: 86 tranny onto 83 engine.
Comments: To: Rick Cooper <rickdcooper@GMAIL.COM>
In-Reply-To:  <CAG12aitfLyR5nQrUgzPY+VHwqozJJTvqxE17fFLCuP6kU0OqAA@mail.gmail.com>
Content-Type: text/plain; charset=utf-8; format=flowed

re getting the splines to start engaging.. I always put the trans in gear, and put the parking brake on.

that way, while rotating the engine by the crank pulley ...you have a good chance of getting the splines to engage.

I had this happen once..long ago on a VW Bug ...the splines of the disc got buggered up from trying too hard to get the input shaft spines to engage the clutch disc splines. I finally had to remove the clutch disc and carefully clean up the disc's splines with a tiny file.

also .. re the pilot bearing..I have seen dozens of cases where the felt dust seal was left out ( since the retaining ring for it was long lost ) ... I often find it necessary to do a waterboxer pilot bearing and seal completely 'right.'

holding the flywheel .. there is a generic flywheel holder tool ....a bar with a gizmo on the end that will engage most flywheels by the teeth. Though I seldom see them for sale. Forget where I got mine about 25 yrs ago. and of course, there is the classic VW flywheel holder tool that bolts to the engine block.

On 1/5/2016 12:11 PM, Rick Cooper wrote: > Larry, good question, since that could have explained the problem. But > initially, because I intended to not replace the existing clutch assembly, > we didn't remove the pressure plate and simply tried to pop the newer > transmission on after removing the old. So the clutch disk could not have > moved out of center. > > Mark, I'm just reading up on the pilot bearing issue. Guess I'd have to > remove the flywheel to check (which could be a challenge since I'm not sure > I can hold that sucker while unbolting). But I can see the tiny rollers on > that bearing with the flywheel on and they all look good to my uneducated > eye. Should I go further? Should I give them some grease and, if so, any > special type? > > Greg, thanks for the tip -- didn't know that. We were rotating the whole > tranny back and forth trying to get the splines to line up. > > On Tue, Jan 5, 2016 at 12:53 PM, Larry Alofs <lalofs@gmail.com> wrote: > >> Is the clutch disk exactly centered on the flywheel? How did you ensure >> that it is? >> The plastic alignment tool that comes with some clutch kits is often >> rather sloppy. An old input shaft is more precise. >> >> Larry A. >> >> >> On Tue, Jan 5, 2016 at 2:51 PM, Rick Cooper <rickdcooper@gmail.com> wrote: >> >>> Thanks Dean. I'm almost certain that the throw-out bearing was fully >>> retracted (it is now, with the tranny out and unless my helper (youngest >>> son) reset it without mentioning it to me...), but will certainly >>> double-check that when we try again. I can't tell you exactly how big the >>> gap was and can't remeasure now since my son is not avail for a couple of >>> days, but from my visual inspections yesterday, I'd guesstimate the gap at >>> about 1.25 - 1.5 inches. >>> >>> On Tue, Jan 5, 2016 at 11:21 AM, OlRivrRat <OlRivrRat@comcast.net> wrote: >>> >>>> Be Sure that the ThrowOut/Release Bearing is Mounted on the Fork >>>> Properly & >>>> >>>> that it is Fully Retracted ~ Check that the Gap Between Eng' & >>> BellHousing >>>> is Even >>>> >>>> All The Way Around ~ How Big is that Gap when You Get Stymied ? ~ >>>> >>>> ORR ~ DeanB >>>> >>>> >>>> On 5 Jan , 2016, at 12:03 PM, Rick Cooper wrote: >>>> >>>>> I'm trying to replace the manual transmission in an '83 Westy with one >>>> from >>>>> an '86 tintop. Quite simply, I can't get the transmission to mate >>> with >>>> the >>>>> 1.9 engine; there is some mechanical obstruction. I think I'm far >>> enough >>>>> away that the input shaft has not even started into the clutch disc >>>>> splines; the fresh grease I put on the input shaft has not been >>>> disturbed. >>>>> I don't think its an incompatible parts issue since they appear >>>> identical. >>>>> The transmissions are both stamped 091 301 103D, the pressure plates >>> are >>>>> marked "Sachs Typ M228" and the clutch discs are both Sachs and >>> measure >>>>> 228mm in diameter. (The clutch kit from the 1983 is nearly new; the >>> PO >>>>> told me it had been recently replaced and I was hoping to re-use it.) >>>> The >>>>> input shafts appear identical; the clutch disks from both will slide >>> onto >>>>> either one of them. >>>>> >>>>> Why was I replacing the transmission? Gearing problems -- usually >>>>> impossible to shift into first from neutral; usually had to get van >>>> moving >>>>> in 2nd and then downshift to 1st. Also issues shifting from 2nd to >>> 3rd. >>>>> It seemed less expensive to swap in a good used transmission than to >>> have >>>>> that one rebuilt. >>>>> >>>>> Can anyone suggest what the problem might be? (I haven't done many >>>>> engine/tranny swaps, but I'm experiencing deja vu. I once tried to >>> put >>>> the >>>>> engine from an '88 Chev S10 into a 1991 Chev S10. Same problem; could >>>> not >>>>> get the engine to engage with the 91 transmission's input shaft. >>> Turns >>>> out >>>>> that GM had changed the input shaft size in the intervening years.) >>>>> >>>>> Thanks, Rick >>>> >>


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