TheSamba.com :: View topic

Fri Dec 13, 2024 4:41 pm

Hi,

I just had my transaxle rebuilt and I needed a new bell housing. Its a Weddle supplied Diesel Bellhousing. My mechanic is now reinstalling everything and found that the bolts were about 1" short and now the starter appears to be 1 inch short as well, it won't engage with the flywheel. I don't have the old bell housing to compare, the rebuilder is in the states and I'm in Canada.

The original bell housing came from Europe (the conversion was done in Europe). Has anybody ever heard of anything like this.

What starter should I be using, any Bosch or Wix part numbers?

Thanks!

Fri Dec 13, 2024 4:45 pm

You’ll want to use a Bosche SR0408X starter + the adapter plate to bolt it to the Diesel Bell housing. Barry at Werke1 might have one on the shelf.

Do you know which flywheel you have?

Fri Dec 13, 2024 4:47 pm

syncroanddestroy wrote: You’ll want to use a Bosche SR0408X starter + the adapter plate to bolt it to the Diesel Bell housing. Barry at Werke1 might have one on the shelf.

Do you know which flywheel you have?

I have the dual mass flywheel. So does this mean I did not have the diesel bellhousing in the first place?

I also have an adapter and a Bosch starter, not sure of the model number.

Fri Dec 13, 2024 4:53 pm

Dual Mass Flywheels only fit inside of the diesel bell housing. Did Russel do your Conversion? I think it rings a bell.

Not sure why your original starter isn’t bolting straight up. 1” is quite a large distance to be off. Unless your original bellhousing was modified in some way, but that’s unlikely. Is your tdi swap at 50° or 15°?

Fri Dec 13, 2024 5:04 pm

Based off this photo: https://www.instagram.com/p/B5Ph39qhgtT/?igsh=YmNubHF3ZDZhNWE5

It looks to me like your engine was installed upright at 15°. If you had a diesel bell housing originally it’s likely your bellhousing was machined down to fit the Ultimate Engineering Adapter plate. The adapter plate allows you to run the diesel bellhousing at the 15° engine orientation, so you can run the DMF.

You’ll have to have the new bell housing machined on the engine mating side, down by the thickness of the adapter plate. Don’t forget to have the dowel holes machined the same distance!

Fri Dec 13, 2024 5:15 pm

Yes, Russel did the conversion for us.

The rebuilder still has my old bellhousings...says its definitely a diesel but it has been shaved down about ½-¾ inch or so where it mounts to the engine.

I don't know why that would have been done.

Everyone is at a loss as to why.

In the end German Transaxle is doing me a solid, sending the old bellhousing up and crediting me the new one when I send it back.

Fri Dec 13, 2024 5:18 pm

My guess is it was modified for the adapter plate. I know Russel has used them on conversions in the past. I bought the same one from Tim at Ultimate Engineering and his instructions were to mill 16mm off the bell housing - which sounds exactly like your issue.

Fri Dec 13, 2024 6:11 pm

That makes total sense. I have sent a message off to Russel for verification.

I have the old housing being sent to me. I'll take it and the new housing to a shop for machining.

All should be good.

Thanks, I think the problem/reason has been solved.

Fri Dec 13, 2024 6:20 pm

There was a bellhousing for upright installs of 4 cylinder engines. It takes a unique flywheel and input shaft. The input shaft is about an inch longer which I assume is because the bellhousing is taller. I can only see photos you upload to Samba. I needed one of these input shafts for a customer some years ago. I may have gotten one of the last.

My suggestion is to stop. Remove the transmission and post some pictures. The input shaft length is critical. I don’t believe a DMF setup will work if you have one of these upright bellhousing. Same is true if you are running an adapter plate. The parts required are kit type deals. A diesel bellhousing takes a diesel starter. You can change to a TDI starter and adapter if you have a diesel bellhousing. Not necessary though.

FAS might be a good resource. You need to figure all this out so you don’t damage something expensive. Post up your parts invoice too. I ran a stock diesel flywheel with my TDI for many years without problems. This all should bolt up and work. Sounds like a mismatch of parts.

Fri Dec 13, 2024 6:41 pm

Just curious, but what is the advantage of installing the engine at 15 degrees vs. the original DV angle of 50?

Fri Dec 13, 2024 6:55 pm

I'm not a TDi guy, but I think that:

1. the 15 degree install permits use of the stock ALH or AHU oil pan; and

2. the turbo oil return (drain) hose works better.

Fri Dec 13, 2024 8:01 pm

tdivan82 wrote: Just curious, but what is the advantage of installing the engine at 15 degrees vs. the original DV angle of 50?

More straightforward install for the post 98 model TDI engines (ALH, PD, CR)

Fri Dec 13, 2024 8:09 pm

Howesight wrote: I'm not a TDi guy, but I think that:

1. the 15 degree install permits use of the stock ALH or AHU oil pan; and

2. the turbo oil return (drain) hose works better.

syncroanddestroy wrote: More straightforward install for the post 98 model TDI engines (ALH, PD, CR)

Ah ha, that makes sense. Thank you gentlemen.