On Mon, May 18, 2009 at 1:25 PM, pdooley <psdooley@verizon.net> wrote:
> Some input shafts will bind in these conversions. �Not sure if it's the
> diesel input shaft or the WBX.
> The shaft is a little long and will bottom in the I4 crank snout, binding
> the motor and putting huge stress on the trans bearings and engine thrust
> bearings.
>
> The input shaft can be clearanced with an angle grinder, just lop off a
> quarter inch or so.
> Of course, do a dry run on your setup to see if clearancing is even
> necessary.
>

The diesel shaft should be the correct length as is. No need to cut.

Though I used a KEP adaptor plate, I had to cut the input shaft on my
air cooled tranny. I'm *just* about certain the WBX shaft also needs
to be cut.

To give a rough idea, cut, input shaft on my swap sticks out just over
1/2" from clutch housing face:

http://tubaneil.googlepages.com/InputShaftCut.jpg/InputShaftCut-full;init:.jpg

A set of calipers should aid in determining length. Shaft should be
long enough to ride properly in pilot bearing, but not so long that it
butts up against hole in flywheel. Hole in FW may be tapered near end.

I used a Dremel with proper metal cut off wheel. Took my time, kept
wet rag on shaft.

Consider installing a windage tray.

It's possible your '91 engine won't have a pilot bearing. On my ABA
swap, I installed a 15mm long PB. IIRC, it was for a Fox engine and
AFAIK, is a sealed type. It sits flush with face of KEP "Vanagon"
flywheel. Pic shows Vanagon bearing on RH and one I installed on LH.
No issues so far. (knocks wood  ;) I can provide a couple of PN's.
Bills don't show which is which.

http://tubaneil.googlepages.com/abaswappilotbearing

Check for excessive play between clutch cross shaft and bushings.

Neil.

-- 
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines