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Fri Nov 06, 2009 4:00 pm

I have a H.......1965 single port 1500 cc engine that I am trying to get into my Super. The engine came with the car but not installed. I tried to get this engine in once before and could only get as far as the engine case studs going about 1/2 inch into the transaxle.

While I had it out I decided to replace the clutch. Today I am trying to get the motor installed. I get to the same place. I get the studs to rest in the transaxle but cannot get it to go the last inch and mesh with the transaxle.

I ordered and used the clutch alignment tool. I know that should not be the case. Might it be a 6 V flywheel that is on the engine instead of a 12 V? Would the issue be the wrong clearance for the flywheel and starter? I am stumped.

Fri Nov 06, 2009 4:01 pm

and if it is an issue of wrong flywheel, how do I tell which flywheel I have? The new clutch was a 200 mm clutch that fit just fine. I am digging for answers. I will leave it up the the experts to guide me.

Fri Nov 06, 2009 4:08 pm

Did you check the bearing in the gland nut? Also might the end of you trans shaft be worn that it isn't fitting in the afore mentioned bearing.

Fri Nov 06, 2009 6:23 pm

I will give those a check. I did not even think about that.

Sat Nov 07, 2009 4:27 am

If everything looks like it will clear do you have the car low so it will slide in? Keeping the car really low works very well for me ask me how I know :oops: . It is almost like you find a sweet spot and it wiggles right in. Hope this helps you out and good luck

Sat Nov 07, 2009 4:56 am

make sure the clutch doesnt have the collar for the throw out bearing in the center on the fingers

71 on use no collar
most clutches now have a removable one so they can be used on both pre 70 with the collar and post 71 without

Sat Nov 07, 2009 7:06 am

Buggin_74 wrote: make sure the clutch doesnt have the collar for the throw out bearing in the center on the fingers

71 on use no collar
most clutches now have a removable one so they can be used on both pre 70 with the collar and post 71 without

Good post.

Sat Nov 07, 2009 7:52 am

Clutch sticky has good info and pictures showing the differences.

http://www.thesamba.com/vw/forum/viewtopic.php?t=148307

Sat Nov 07, 2009 8:11 am

Everything else has already been covered...

I found it necessary, often as not, to 'bump' the pulley or flywheel just a bit to get the input and clutch disc splines to line up (if you're using ramps - tires are on the ground and can't be rolled). Otherwise, if you're off the ground, put the car in a gear and bump a wheel to move the input shaft.

That's what it sounds like to me - you'll go as far as the splines and stop. Try giving 'er a bump!

Could be damaged input/disc splines, too. Didja try and 'dry fit' the clutch disc on the transmission input prior to install?

Sat Nov 07, 2009 9:17 am

Alister wrote: Everything else has already been covered...

I found it necessary, often as not, to 'bump' the pulley or flywheel just a bit to get the input and clutch disc splines to line up (if you're using ramps - tires are on the ground and can't be rolled). Otherwise, if you're off the ground, put the car in a gear and bump a wheel to move the input shaft.

That's what it sounds like to me - you'll go as far as the splines and stop. Try giving 'er a bump!

Could be damaged input/disc splines, too. Didja try and 'dry fit' the clutch disc on the transmission input prior to install?

I did dry-fit the clutch prior to install. I am going to take a closer look at the clutch and throwout bearing combo. I also have been bumping the motor by moving the pulley. I hope it goes in today. It is driving me a little crazy.

Thanks for all the info and pictures everyone. These are all great ideas.

Sat Nov 07, 2009 9:44 am

Just took the motor down. I have the right clutch and throwout bearing combo. While I had it down I tried putting the clutch alignment tool in again, and it will not go in. Looks like I may have moved the clutch somehow. Guess I am dropping the motor off the jack and trying to get the clutch back in place :~

Sat Nov 07, 2009 11:05 am

one4house wrote: Guess I am dropping the motor off the jack and trying to get the clutch back in place :~

You likely can loosen the pressure plate bolts, then insert the alignment tool to line stuff up, then re-tighten and torque the pressure plate bolts all while the engine stays on the jack. You can wedge the stock wheel bolt socket between the flywheel teeth and the exhaust connecetion to keep the flywheel from turning...

Sat Nov 07, 2009 7:21 pm

one4house wrote: Just took the motor down. I have the right clutch and throwout bearing combo. While I had it down I tried putting the clutch alignment tool in again, and it will not go in. Looks like I may have moved the clutch somehow. Guess I am dropping the motor off the jack and trying to get the clutch back in place :~

i had that issue on my 71 standard. i dont know why, its never happened before. that disk would move out of alignment. it took me three tried to get it right. ridiculous :roll: