Help i can't get the new gearbox on

[gti mad man]

Hi guys got the shim seal flywheel clutch plate and cover plate on but the gearbox wont fit on all the way i can get it on the 2 studs but it just wont go the last bit so far ive

1) centred the clutch correctly with a spline tool
2) tried moving the centre spline
3)made sure the input shaft was burr free

any other ideas

[Fritz]

But did you try the new clutch centre plate on the splines of the box before you bolted it up to the flywheel ?


It could be the wrong one....


Regards


Fritz,,,,,,,,,,

[gti mad man]

doh no i didnt thoiugh the splien tool fits the new and old clutch fien so assume there the same

[toomanytoys]

Just done the clutch on Flibertyjibbets van today...
near pefect alignment is required.. both the clutch plate and the box going onto the engine..
took clutch off and realigned it even more carefully..
also putting it in a gear and holding and turning the cv flanges on the box helps the input shaft if it gets hooked up...


Oh and before its back in... did you check the tips of the release bearing arms are nice and "rounded" where they press on the bearing?? if they have flats and angles... the clutch can get stuck.. if need be build up the "rounds" with a bit of weld and file back to a nice curve.. (also had to do this on Julies bus today)

[Ian Hulley]

i can get it on the 2 studs but it just wont go the last bit

Have you burred over the edge of the spigot bearing ?

Ian.

[gti mad man]

Dam these boxes wanna be exact don't they lol took these picss if they help?

im sure nothings burred?

its a luk clutch

[Ian Hulley]

The spigot bearing is in the end of the crankshaft, if the outer lip ( ) is burred over the gearbox input shaft won't slide in ( ) properly and the box will be ~15mm apart from the engine.

Ian.

[gti mad man]

That this thing in the middle?

looks ok ?

[Ian Hulley]

That this thing in the middle?

looks ok ?

Yep, looks OK ... have you tried the box in without the clutch ? make sure it 'goes all the way' ... so to speak

Ian

[skell]

gtimadman - you trying to do this on your own, I struggled with mine for ages, phoned a friend and did it in a minute!

[CovKid]

Heh heh - damned annoying at times I know. Even in my beetle days I'd still hit this problem from time to time. I actually got rather good at lining the clutch up by eye but crucially the angle has to be spot on for starters. The above suggestions are pretty good, though sometimes a good shove does it.

[mirams]

I had bother when I was doing this and it needed incredibly careful alignment of the clutch, then straight in no bother.

[mike_gee32]

I've just done this this morning, same luk clutch as well by the look of it, alignment is very important and quite hard to get right on your own I was balancing the engine on one trolley jack and the gearbox on another and it also seemed to stick about 15-20mm out. I took hold of both drive flanges and turned them the same way while pushing against the gearbox, about half a turn on the flanges and it suddenly slid on perfectly.

Good luck

[Aidan]

top tip is to cable tie the clutch arm lever in the fully retracted position so the release bearing doesn't come into play whilst fitting. As soon as you press the pedal the cable tie will snap and the release bearing will be doing it's job

this tip copyright BAXTER

alignment is everything, ensure the face of the bellhousing is parallel to the engine, a few degrees will cause allignment issues, ideally you need adjustability in all palnes when offering it up which usually means two peeps or a clever device on the jack