Be Sure that the ThrowOut/Release Bearing is Mounted on the Fork Properly &

that it is Fully Retracted ~ Check that the Gap Between Eng' & BellHousing is Even

All The Way Around ~ How Big is that Gap when You Get Stymied ? ~

                                                        ORR ~ DeanB

                                                	
On 5 Jan , 2016, at 12:03 PM, Rick Cooper wrote:

> I'm trying to replace the manual transmission in an '83 Westy with one from
> an '86 tintop.  Quite simply, I can't get the transmission to mate with the
> 1.9 engine; there is some mechanical obstruction.  I think I'm far enough
> away that the input shaft has not even started into the clutch disc
> splines; the fresh grease I put on the input shaft has not been disturbed.
> 
> I don't think its an incompatible parts issue since they appear identical.
> The transmissions are both stamped 091 301 103D, the pressure plates are
> marked "Sachs Typ M228" and the clutch discs are both Sachs and measure
> 228mm in diameter.  (The clutch kit from the 1983 is nearly new; the PO
> told me it had been recently replaced and I was hoping to re-use it.)  The
> input shafts appear identical; the clutch disks from both will slide onto
> either one of them.
> 
> Why was I replacing the transmission?  Gearing problems -- usually
> impossible to shift into first from neutral; usually had to get van moving
> in 2nd and then downshift to 1st.  Also issues shifting from 2nd to 3rd.
> It seemed less expensive to swap in a good used transmission than to have
> that one rebuilt.
> 
> Can anyone suggest what the problem might be?  (I haven't done many
> engine/tranny swaps, but I'm experiencing deja vu.  I once tried to put the
> engine from an '88 Chev S10 into a 1991 Chev S10.  Same problem; could not
> get the engine to engage with the 91 transmission's input shaft.  Turns out
> that GM had changed the input shaft size in the intervening years.)
> 
> Thanks, Rick