OK,

I have tried all the suggestions  and found them all wanting in one way
or another. Even the bushing promised has not shown up.

My final solution: The machine shop gets the flywheel in the morning and
a newly machined bushing is going to be pressed into the wheel. End of
story.

It's a h*ll(deference to the moderators)  of thing to have to go through
for an $0.80 part that is crucial.. VW ought to have it's collective
butt kicked for this nonsense.

John Rodgers
88' GL Driver

John Rodgers wrote:
> This has become an issue with me. When the transmission was removed from
> my van, it was discovered this sleeve was missing, as well as the felt
> washer that is also supposed to be there.
>
> Here's the deal....
>
> The flywheel has a sleeve pressed into the hole in the center of the
> wheel. The sleeve fits flush on the front (front of the vehicle site)
> side of the wheel, and leaves a recess on the back side(crankshaft
> flange side) of the wheel. A felt washer fits into the recess and
> together they serve as a seal to the front of the needle bearing in the
> end of the crank with the felt against the bearing. The transmission
> input shaft goes through this whole assembly of flywheel, sleeve, felt
> washer and into the needle bearing in the end of the crank.
>
> The rub.  When a flywheel goes to the machine shop for refacing during a
> clutch job, the sleeve gets punched out so the wheel will fit right on
> the lathe for proper alignment for refacing of the wheel. Trouble is,
> the sleeves never get put back in. Apparently the machinists think the
> sleeve is one of those little pieces that gets replaced during the
> repair, so he doesn't other with keeping up with it. The wheel goes back
> to the shop, and the mechanic there doesn't know the difference or
> doesn't care, and puts it back together without the felt washer and
> sleeve. With no sleeve and felt asher, in time needle bearing grease
> works it's way along the input shaft to the clutch disk face and trouble
> begins.
>
> After talking with a lot of people, it appears some mechanics don't
> think these two little parts are significant, while others feel they
> are. I had a nice little chat with Daryl at AA Transaxle and he told me
> that he sees numerous tranny input shafts damaged due to loss of the
> grease which resulted from no felt washer and flywheel sleeve to hold
> the grease in place. He recommended they be installed. After careful
> consideration I agree. It makes sense. It was engineered that way for a
> reason, so I am going to effect the proper repair on this - it gets a
> sleeve and felt washer.
>
> Here's the rub. All of the list vendors carry the felt washer, but
> nobody including some VW dealers parts departments has the flywheel
> sleeve. I find that really odd. With out the sleeve, the felt washer can
> back away from the needle bearing assembly by a full inch at least. What
> good does the felt washer do in that position.
>
> So - does anyone have a clue where this sleeve can be acquired. It is a
> simple piece, and I feel it important for a proper repair, yet I cannot
> find it.
>
> Thanks,
>
> Regards,
>
> John Rodgers
> 88 GL Driver
>
>