Sometimes the old pilot bearing is difficult to remove. During the
brutal efforts to remove it part of the old shell gets left behind.
Perhaps someone just pounded the remains of an old bearing shell deeper
into the hole thinking it would be out of the way. Or maybe they gouged
the hole with a chisel removing the shell. It happens. You are going to
have to get a really good look in there. A Dremel with a small stone
will fix whatever it is. BTDT

Mark

VW4X4@FYI.NET wrote:
>
> 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
>