I had the exact same problem nearly a year ago. I thought I was doing
something wrong, and went back to the FLAPS for another bearing to try
again. I had the original bearing and discovered that the new bearing was in
fact too big. Went back to FLAPS, with the original as a sample, and we
found that some of the pilot bearings in the bin, with the correct stock
number, were the wrong bearing. He had some others with a different brand
name, same stock number, that were the right size. So somewhere in the
supply system there are some incorrectly labeled pilot bearings!

John Philcox
'85 GL, Newport, RI

> -----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