1600 Engine will not fit in Standard Tranny

[VW_Jimbo]

With the engine is in as in the first pictures. Take a wrench and turn the crankshaft, then jiggle the engine, turn the wrench - jiggle, push in engine, turn the wrench - jiggle, push....on and on, till everything becomes aligned.

Be certain the engine is in line with the transmission input shaft, from front to rear. It needs to be in the same plane! Or you will be fighting the input shaft.
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Jimbo

There is never enough time to do it right the first time, but all the time necessary the second time!

[viiking]

As above. The engine is not in the same plane as the gearbox.

Loosen gearbox mounts and use a jack(s) to move box/engine so that motor starts to slide in at the exact plane that the transmission is.
_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[Pruneman99]

I haven't put and engine in a later trans with the throwout bearing sleeve in awhile, so I could be wrong but does something look funny there? That black collar? I want to say from memory that the sleeve the throwout bearing rode on was just a thin metal tube..

[vs-works]

[viiking]

[Dan the workingstiff]

I am not suggesting you do this....

I am questioning those in the know. While a youngster many years ago, under the influence of older more knowledgeable than I was told to "take the tip off the input shaft, its too long".

I know I did it at least once 30yrs ago, was that on a bus trans install, maybe?
_________________
'69 Beetle
'66 FG buggy
My other air-cooled's
'76 IH 1200
'75 IH 1200

[frenchroast]

[[email protected]]

Maybe take another look at the gland nut. I once had one machined incorrectly that had the pilot bearing flush with the end of the nut face. This allowed the engine/clutch to go on the input shaft, but the spline portion of the input shaft would bottom out in the bearing before the engine would touch the trans.

You could also see if you can get an actual input shaft to use as an alignment tool. I used the plastic alignment tools for a long time until I started working on transaxles and got an input shaft damaged at the other end to use as an alignment tool. I was amazed how much easier the engine went in with the actual steel input shaft.

[raydog]

Have you put the transmission in gear? Any gear, to keep the input shaft from turning while trying to line up the splines.
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Come on, It's not rocket science. KISS

[anthax]

I've had an issue with a friction disc, where the splines where badly machined and wouldn't go on the splines on the input shaft. Had to sand a small amount in every groove until it would fit.

[Busstom]

OP's probably out working on it, but...

While it is a PITA at this point, the gland nut and clutch disc can be fitted over the input shaft (as applicable) to test fit and test all these theories. The flywheel can be removed and hand-placed into the bell housing space (though unless done squarely and evenly, I'm not sure just how helpful this could be).

[Jim Schield]

Did you loosen the wing nut on the transmission clutch arm? I mean loosen it considerably. Otherwise you are fighting the spring and will never be able to push on the engine all the way to the transmission.

[Joey]

[Cusser]

[rcooled]

[Marinablau703]

[Weezle]

I had this same problem, the lower mount studs were too long and I ground them down, but also the longer studs that come out of the engine block on the bottom were ever so slightly bent upwards, possibly from shifting during shipment. I replaced those with true and straight studs and I got my engine in. It was still difficult but it went.
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I got a fever, and the only prescription is more beetles!

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[ashman40]