On Mar 20, 2010, at 1:46 PM, neil n wrote:

>
> 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.

Well..... I don't want to be the bearer of bad tidings, but the last
time I used the nuts to mate a reluctant trans to the motor I ended up
replacing the gearbox the following summer..  The reluctance was due
to the pilot shaft bearing being turned to little bitty pieces.  A
year and about 5,000 miles later the input shaft seal failed.  That's
when I found the deeply scored input shaft. The good news was that I
just happened to have a 'spare' gearbox and motor waiting to go in so
down time was minimal. But without waiting spares it would have been a
real 'Aw s....'

I don't think that I'll "pull" them together again. Start your search
for an input shaft or gearbox just in case.

Jim