re getting the splines to start engaging..
I always put the trans in gear, and put the parking brake on.

that way, while rotating the engine by the crank pulley ...you have a
good chance of getting the splines to engage.

I had this happen once..long ago on  a VW Bug ...the splines of the disc
got buggered up from trying too hard to get the input shaft spines to
engage the clutch disc splines. I finally had to remove the clutch disc
and carefully clean up the disc's splines with a tiny file.

also ..
re the pilot bearing..I have seen dozens of cases where the felt dust
seal was left out ( since the retaining ring for it was long lost ) ...
I often find it necessary to do a waterboxer pilot bearing and seal
completely  'right.'

holding the flywheel ..
there is a generic flywheel holder tool ....a bar with a gizmo on the
end that will engage most flywheels by the teeth.
Though I seldom see them for sale. Forget where I got mine about 25 yrs
ago.
and of course,
there is the classic  VW flywheel holder tool that bolts to the engine
block.

On 1/5/2016 12:11 PM, Rick Cooper wrote:
> Larry, good question, since that could have explained the problem.  But
> initially, because I intended to not replace the existing clutch assembly,
> we didn't remove the pressure plate and simply tried to pop the newer
> transmission on after removing the old.  So the clutch disk could not have
> moved out of center.
>
> Mark, I'm just reading up on the pilot bearing issue.  Guess I'd have to
> remove the flywheel to check (which could be a challenge since I'm not sure
> I can hold that sucker while unbolting).  But I can see the tiny rollers on
> that bearing with the flywheel on and they all look good to my uneducated
> eye.  Should I go further?  Should I give them some grease and, if so, any
> special type?
>
> Greg, thanks for the tip -- didn't know that.  We were rotating the whole
> tranny back and forth trying to get the splines to line up.
>
> On Tue, Jan 5, 2016 at 12:53 PM, Larry Alofs <lalofs@gmail.com> wrote:
>
>> Is the clutch disk exactly centered on the flywheel?  How did you ensure
>> that it is?
>>    The plastic alignment tool that comes with some clutch kits is often
>> rather sloppy.  An old input shaft is more precise.
>>
>> Larry A.
>>
>>
>> On Tue, Jan 5, 2016 at 2:51 PM, Rick Cooper <rickdcooper@gmail.com> wrote:
>>
>>> Thanks Dean.  I'm almost certain that the throw-out bearing was fully
>>> retracted (it is now, with the tranny out and unless my helper (youngest
>>> son) reset it without mentioning it to me...), but will certainly
>>> double-check that when we try again.  I can't tell you exactly how big the
>>> gap was and can't remeasure now since my son is not avail for a couple of
>>> days, but from my visual inspections yesterday, I'd guesstimate the gap at
>>> about 1.25 - 1.5 inches.
>>>
>>> On Tue, Jan 5, 2016 at 11:21 AM, OlRivrRat <OlRivrRat@comcast.net> wrote:
>>>
>>>>          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
>>>>
>>