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Fri May 11, 2012 7:07 pm

Hello, I'm currently having a problem I cannot seem to fix. I recently bought a rebuilt longblock cb case built to 1800 . Got the motor all put together got it started and did the 20 minute break in, it ran good. After this I started it again to see how the new clutch felt and it will not disengage. I have a new t/o bearing, pilot bearing, clutch disk, pressure plate, resurfaced flywheel and clutch cable . Free play is good. I have played with washers on the bowden tube to no avail. I dropped the motor again pulled the clutch pilot bearing looks brand new as it is, and greased, cleaned the input shaft splines added a very small amount of grease and made sure the disk slid smoothly on the splines. I used a centering tool and retorqued the clutch bolts to 18 ft lbs. The tranny and engine mated up very smooth, and I kept them even the whole time . Reinstalled motor, and same issue. I'm at my wits end I feel like I'm doing everything right and its still not working. I will add that I am using an 091 tranny, and I can shift gears when the engine is off. Thanks for any help and I have read many posts on here that describe similar issues and I have tried everything that some of these posts suggest but no fix.

Fri May 11, 2012 7:34 pm

.delete

Fri May 11, 2012 7:51 pm

Thanks for the tips but the braket that bolts to the tranny is in good shape and the cable is brand new. I have had my girlfriend work the clutch while I was watching it . I also made sure I have the clevis pin and pedal installed correctly. FYI I made it home once with a broken cable by starting in first then just matching rpms and shifting without a clutch, you want to avoid stops signs using this method though.

Fri May 11, 2012 7:53 pm

MtCamper,
Do you have a 228mm flywheel on the engine to match the 091
bell housing.

You said you TOOK the pilot bearing out and it looked ok?

brand of clutch parts and what pilot tool did you use?

Proper clutch pedal freeplay?

Disc splines lubed and pilot shaft in good shape?

Fri May 11, 2012 8:03 pm

mtcamper wrote: Hello, I'm currently having a problem I cannot seem to fix. I recently bought a rebuilt longblock cb case built to 1800 . Got the motor all put together got it started and did the 20 minute break in, it ran good. After this I started it again to see how the new clutch felt and it will not disengage. I have a new t/o bearing, pilot bearing, clutch disk, pressure plate, resurfaced flywheel and clutch cable . Free play is good. I have played with washers on the bowden tube to no avail. I dropped the motor again pulled the clutch pilot bearing looks brand new as it is, and greased, cleaned the input shaft splines added a very small amount of grease and made sure the disk slid smoothly on the splines. I used a centering tool and retorqued the clutch bolts to 18 ft lbs. The tranny and engine mated up very smooth, and I kept them even the whole time . Reinstalled motor, and same issue. I'm at my wits end I feel like I'm doing everything right and its still not working. I will add that I am using an 091 tranny, and I can shift gears when the engine is off. Thanks for any help and I have read many posts on here that describe similar issues and I have tried everything that some of these posts suggest but no fix.

You have covered the basics.

I suggest the other party with a clutch problem start your own thread rather than hijack so we don't all get confused.

With the cable loose or off, can you move the lever by hand on the trans and feel / hear the TO hit the clutch disc?

As Old DKP Driver asked - what brand of disc and clutch did you buy? Is it a 3 finger clutch or a diaphragm clutch?

Diaphragm style

Older 3-finger style (some have TO ring some do not) This one is off a corvette as I could not find a good photo of a VW one but some early 70's bay clutches had 3 fingers instead of a diaphragm. The change to diaphragms came in the early 1970's. Even as late at 1983 some cars were still using 3-finger clutches with replaceable springs.)

Fri May 11, 2012 8:19 pm

I can feel and here the throw out bearing hit the pressure plate. It is a sachs clutch and pressure plate. I believe it is a 210 clutch/flywheel I'm not sure though as the engine builder (out of state) provided it . I looked up the part number on the box 022141025gk and it said it is for a 1700, and from what I reasearched should work no? All things considered I'm starting to think this pressure plate is not the right one.

Fri May 11, 2012 8:20 pm

Old DKP driver I did not remove the pilot bearing but installed a brand new one. Also cleaned and lubed the splines

Fri May 11, 2012 8:27 pm

An 091 transmission requires a 228mm flywheel and the corresponding clutch components, along with the correct starter. You've got the wrong parts in there.

Fri May 11, 2012 8:34 pm

Do you want to play 20 Questions.... :idea:

Caus, you need to Speak up about your engine exchange and the 091 trans. :roll:

YOU HAVE A 210 mm flywheel Do you also have the 002 bell housing
and input shaft.

was all well BEFORE you got the exchange engine.

Did your bus sit along time and possibly the rear brake drums are
rusted to the linings????

Fri May 11, 2012 8:35 pm

mtcamper wrote: I can feel and here the throw out bearing hit the pressure plate. It is a sachs clutch and pressure plate. I believe it is a 210 clutch/flywheel I'm not sure though as the engine builder (out of state) provided it . I looked up the part number on the box 022141025gk and it said it is for a 1700, and from what I reasearched should work no? All things considered I'm starting to think this pressure plate is not the right one.

when you have 3/4" freeplay at the pedal, how much adjustment is left on the threads? Did you replace the cable or do anything in the pedal area that might have changed something?

Fri May 11, 2012 8:43 pm

SGKent It did not have many threads left probably a 1/4 inch. Olddkpdrive not trying to play 20 ?s I'm just stumped 2nd engine pull in 24hrs. Everything was working previously, brakes are free tires spin freely. Engine is as described in op cb case built to 1800. From all the reasearch I have done it should be possible to run a 1700 /1800 with an 091 here is the thread I asked this question on http://www.thesamba.com/vw/forum/viewtopic.php?t=397410&highlight=swap++1800 thanks for your help guys.

Fri May 11, 2012 8:51 pm

mtcamper wrote: From all the reasearch I have done it should be possible to run a 1700 /1800 with an 091 here is the thread I asked this question on http://www.thesamba.com/vw/forum/viewtopic.php?t=397410&highlight=swap++1800 thanks for your help guys.

Nobody said it wasn't possible to run that engine with an 091 transmission but you need to use parts that are compatible with that transmission.

Fri May 11, 2012 9:01 pm

I think you will find the input shaft is too long and bottoming out
and will not spin.

Fri May 11, 2012 9:03 pm

just to be clear - are the transmission, bell housing, and flywheel the same ones as before the engine swap?

Fri May 11, 2012 9:04 pm

That does sound like a possibility thanks. Any way to put one from an 002 or cut mine? I think this whole deal might just be easier to use my old 228 flywheel and get a new clutch for that.

Fri May 11, 2012 9:06 pm

SGKent tranny and bellhousing are the same flywheel is different. My old motor has the 228 and I think this one is a 210 . It is also a diaphram pp.

Fri May 11, 2012 9:11 pm

Do you still have your 002 trans?
as you can swap the input shafts or, cut 1/2 in. off the 091.

Fri May 11, 2012 9:22 pm

I never had an 002. So it I were to cut the 091 shaft it is 1/2 inch? The engine is replacing a 2.0 I had sorry I should of included this info its a 79 westy. I know probably not the best bet to go with an 1800 but it was the best finacial choice for me as my 2.0 was toast.

Fri May 11, 2012 9:32 pm

What year is your Bus?

You should have it posted in your sig. line. :?

Pull the clutch assembly off the engine.
put the disc on the input shaft and see if it moves freely.

Also what did you use for the centering tool.????

Fri May 11, 2012 9:33 pm

mtcamper wrote: I never had an 002. So it I were to cut the 091 shaft it is 1/2 inch? The engine is replacing a 2.0 I had sorry I should of included this info its a 79 westy. I know probably not the best bet to go with an 1800 but it was the best finacial choice for me as my 2.0 was toast.

Send the pressure plate back and use the flywheel that goes with the transmission. I think that would work but a couple other people here will know that answer.

If I understand - you had a 2.0 and you replaced it with an 1800?