On 3/20/10, Scott Daniel  - Turbovans <scottdaniel@turbovans.com> wrote:

> It's not together yet ?

Heh. Almost.

Swap was driving fine, but removed "original" DK as it has a funny
noise coasting in 1st/2nd at low speed. DK currently being installed
is one I bought used. Am hoping it's ok. If so, I may attempt a
rebuild of noisy DK. Ha!

> one, if using diesel vanagon flywheel on an inline four engine in a vanagon
> with DK trans or input shaft ..
> the DK shaft has to be shortened about 12mm from stock.......

Thanks. For sure. I did this at time of swap.  Dremel worked for me.    :)

I'm sure you know this, but for others, I recently learned that the DV
pilot bearing is a sealed unit. I installed a slightly longer (Fox?)
PB thinking it might be a sealed unit. (no felt ring required?)
Doesn't look like the DV PB I just bought. It has a seal. Still, Fox
one still looks fine after ~ 13K Km's. Next clutch, I'll install the
DV PB.

>
> Always put the trans in any gear, and put the parking brake on ...
> so as you are conencting engine and trans you can rotate the crank pulley a
> little bit to line up splines.

Good tip. Yup. Did that

>
> I have seen where after a lot of horsing around and not getting the splines
> to engage ....the splines of the clutch disc got damaged a little....so they
> could never engage. Solution was to pull engine and trans back apart, repair
> those splines with a tiny file.  So make sure that doesn't happen.

Good to know. Same as cleaning up splines on end of a damaged half
shaft I bet. (BTDT)

I guess my question should have been simpler.

Like:

If splines UNdamaged prior to tranny R&R, is it possible for "new"
tranny to fully mate to engine if splines misaligned?

From what you've said, seems not.

> and you kinda gotta have a plastic dummy input shaft  ( comes with a clutch
> kit, I have several left over ones I'd sell )
> or a real input shaft for a clutch alignement tool.
> If you just try to eyeball it ...you can ...
> but that's tricky.
> If I had just eye-balled the centering of the disc in the pressure
> plate/flywheel , I'd be extra careful about forcing it.
>
> You probably have it together by now anyway I bet !

Clutch was already installed/working right. This conversion was driving fine.

Tranny is now mated to engine. Just needs buttoning up.

Thanks,

Neil.

>
> ----- Original Message -----
> From: "neil n" <musomuso@GMAIL.COM>
> To: <vanagon@GERRY.VANAGON.COM>
> Sent: Saturday, March 20, 2010 11:58 AM
> Subject: Re: Trans. Install: Input shaft & clutch splines
>
>
>> Thanks Dylan.
>>
>> Clutch was already installed and aligned/working right. For sure.
>> Clutch tool is handy.  :)
>>
>> So it's possible to get engine in with splines misaligned?
>>
>> Didn't feel like I forced engine in, but I used nuts to pull tranny to
>> engine (each a bit by bit carefully, engine moved easily though) so
>> needed to ask. Last time IIRC, tranny eventually went in "by hand".
>>
>> Neil.
>>
>> On 3/20/10, dylan <insyncro@yahoo.com> wrote:
>>> forcing it will do damage to the splines.
>>> not recommended.
>>> get a clutch alignment tool.
>>> they are given with complete clutch kits.
>>> makes the job very simple.
>>>
>>> dylan
>>>
>>>
>>>
>>>
>>> ________________________________
>>> From: neil n <musomuso@GMAIL.COM>
>>> To: vanagon@GERRY.VANAGON.COM
>>> Sent: Sat, March 20, 2010 2:52:08 AM
>>> Subject: Trans. Install: Input shaft & clutch splines
>>>
>>> Hi all.
>>>
>>> When installing the transmission, is it obvious if input shaft/clutch
>>> splines aren't lining up? Is it possible the transmission can be
>>> "forced" in even if splines misaligned?
>>>
>>> I'm not totally unfamiliar with VW transaxle remove/install, but
>>> tonight, it was a royal PAIN. (don't ask) Anyhow, when things finally
>>> lined up, and enough thread was showing on lower studs, I used lower
>>> nuts, then uppers, to bring the transmission and engine together. It
>>> all "felt" ok while doing this, but because I had to use the nuts, I'm
>>> asking the above. FWIW, I did jockey the crank back/forth to help make
>>> sure splines lined up.
>>>
>>> ** For others running an I4 with carrier ~ in middle of block, with
>>> transmission removed, engine might tilt toward rear of vehicle. MIne
>>> did. Jacking up pulley end of engine to normal position obviously
>>> helps to line up studs. Before I did this, the rear portion of the
>>> transmission was hanging up on cross member, barely allowing lower
>>> studs to pass through clutch housing holes.
>>>
>>> Oh and if you're using a KEP, be mindful of that longer stud. Not sure
>>> if all KEP/VW use this, but mine does.
>>>
>>> Thanks!
>>>
>>> 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
>>>
>>
>>
>> --
>> Neil Nicholson '81 VanaJetta 2.0 "Jaco"
>>
>> http://tubaneil.googlepages.com/
>>
>> http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines
>>
>
>

--
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

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