I have removed some thickness from the back side of those seals to get them
below flush..Not the flywheel side, but the eng side of it. As long as its
level/straight in the bore and below flush, it will work  Get Viton or
similar quality seals from the likes of Ken @Vanagain and you should have no
problems.
Daryl of AA Transaxle
(425) 788-4070
aatransaxle.com
86 Syncro Westy
Zetec in the trunk
----- Original Message -----
From: "John Rodgers" <inua@CHARTER.NET>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Thursday, March 19, 2009 1:45 AM
Subject: Front Oil Seal vs Flywheel Seal vs Bob Donalds Installation Video

> Ok - 88 GL Manual Tranny is sitting on the shop floor on a dolly.
> Flywheel removed, old oil seal removed, old pilot bearing removed, seat
> for both cleaned up. Flywheel clutch disc contact face cleaned and
> scuffed, new flywheel "O" ring installed, new pilot bearing greased and
> installed, New oil seal put in place and tapped down per Bob Donalds and
> bottomed out.
>
> But WTF! The new seal won't recess the 1/16 below the surface of the
> case as Bob  specifies! It only recesses 1/32 of an inch. Hmmm~wrong
> seal perhaps?  A quick call to Ken Wilford, my supplier for the seal.
> raised an interesting queston. How did the seal supplied copair with
> others of other brand names. Well, as it turns out the two after market
> seals he sell and the genuine Volkswagen OEM seals he handles are all
> the same thickness. So no discrepancy there.
>
> This raises a question. I understand fully why Bob insisted the seal be
> recessed - to avoid ripping the thing out at some point and having to do
> it all over again. So with this apparent difference between how the
> seals are made vs how Bob says the need to be installed - it appears
> there is something missing.if the information on how to get this done
> best.
>
> So the question. Can I remove 1/32 of material from the seal lip to get
> the recess correct? Is there enough rubber that when cut back I will
> still not be into the metal n the seal? It's easy enought to remove the
> rubbe - simply by grinding away on a flat surface on some 320 - 600 grit
> wet/dry sand paper. That will keep the lip of the seal true.
>
> Any suggestions anyone?
>
> Also, what is the proper relation of the felt washer to the pilot
> bearing? Is there some other sleeve or something that goes in the
> Flywheel?
>
> Need to know.
>
> Thanks,
>
> John Rodgers
> 88 GL Driver
> Chelsea, AL