Right, that is exactly my problem...the pilot bearing is still inside the
1.8 liter crank and I missed it.  If I was warned about that sometime when I
was collecting info and soliciting advice, it flew right over my head.

 Now, after it's been pointed out, that bearing is fairly obvious, but as I
was doing the original project, I didn't notice it 'hiding' inside there.  I
do recall that as I made my homemade clutch centering tool, there was some
slight difference as I went to install the clutch...it seemed not the same
as when I built that tool...I wrote that off to variation in the output
shafts..or something.  Ignorance is the real reason...my first block swap
and clutch on a Vanagon.
   Anyhow, I ordered the parts to do a real clutch job now and a new input
shaft bearing and TO bearing tube...

  I was pretty gentle with the van....though I almost took off for Bishop,
Ca for a bike race, today..That would have been a real big mistake, trying a
2000 mile trip through the Sierras with no pilot bearing...
  Thanks Mark and everyone who responded.  Swepco makes a good "clutch oil"
I guess...
  Don Hanson

On Wed, Sep 22, 2010 at 11:53 AM, mark drillock <mdrillock@cox.net> wrote:

> Don, I think you were warned. The ABA engine from an 93 Jetta does not use
> a clutch pilot bearing and so the hole for it in the crank is empty. If you
> did not acquire and install one you messed up big. The Vanagon requires this
> bearing to support the tranny input shaft. Otherwise the shaft will wobble,
> the tranny seal it pokes through will leak, and the clutch will get damaged,
> bellhousing  may get damaged too, .......
>
>
> Mark
>
>
>
>
> Don Hanson wrote:
>
>>    I've recently had my engine out.  Inline 4 VW/5sp manual tranny.  It
>> went back in with significantly more power (result of a new block).  I
>> re-used the clutch and flywheel from my 1.8liter block, un-touched, on the
>> "new" 2.0liter block.  I did not replace anything.  Everything looked to
>> be
>> in acceptable shape, so I bolted it all up.  Now my clutch is slipping
>> under
>> load.  I have searched everything online on Clutch slipping..and it looks
>> like I have a 'clutch job' to do, but grasping at straws here, I am
>> wondering about cheap/easy fixes, first.  That quote in the subject line
>> goes:  "Wish in one hand, crap in the other hand and see which one fills
>> up
>> first" and is an old Ski Patrol saying from my Jackson Hole days, cleaned
>> up
>> for a family list.
>>
>> ................
>
>
>>   I have oil dripping.  I know now that I should have replaced the pilot
>> bearing and all those nearby seals (which looked good, but..)  I get a
>> spot
>> of about 6" diameter when I park after a highway run...coming from the
>> junction of tranny and engine.  I will be raising the rig back up today to
>> have a look...I could easily have a leaking pan (diesel-style, engine sits
>> in there at 50degree slant) causing that drip...The rear main seal of the
>> 2.0 liter block showed no leaking, so I didn't replace that, either..My
>> tranny was not leaking into the T.O. bearing area, either.
>>
>>   any advice?
>>
>>   thanks,  Don Hanson
>>
>>