Engine Won't Fit On Transmission - What Am I Doing Wrong?

andreasschmieg

I bought a 1967 VW Beetle with an AE 1600 dual port engine in cardboard boxes. I did a ghetto rebuild on the engine reusing everything that still looked decent. Now I tried to install the engine and it will not completely push into the transmission bell housing. I tried for quiet a while. The flywheel seems to fit in the hole.

Any idea what I am doing wrong?

Once I am done being pissed off, I will bolt the clutch assembly to an identical flywheel (without an engine attached to it) and try to just push the clutch and flywheel assembly into the transmission housing.

Or maybe the Beetle knows that this is not the original engine and rejects it :-).

Grrr!!!
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~~~ Dont trust cars under 30! ~~~

60ragtop · Posted: Wed Oct 07, 2015 1:49 pm Post subject:

assuming you used a pilot tool when installing clutch, put the car in gear and the e brake on then rotate the pulley while trying to push the engine in the rest of the way. or hold your tongue on the other side of your mouth Wink

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Rick
Certified Mechanic by the State of Michigan in 1977
ASA certified in 1987
Certified Hunter Wheel Alignment Master Technician 1986

Northof49 · Posted: Wed Oct 07, 2015 2:19 pm Post subject:

Does the clutch plate match the style of throwout bearing? There is an issue of some needing the ring on the pressure plate, and others won't work with it in place if not needed.

There are some good illustrations on this site of the way matching tranny's and clutch plates should look. Wrong combo and it won't go on the final 3/4".
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1958 Karmann Ghia owner

grandpa pete · Posted: Wed Oct 07, 2015 2:23 pm Post subject:

If that doesn't work ; Check the trans numbers...any chance a PO put in an early trans ?
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63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

Northof49 · Posted: Wed Oct 07, 2015 2:30 pm Post subject:

Check out this excellent thread:

http://www.thesamba.com/vw/forum/viewtopic.php?t=148307
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1958 Karmann Ghia owner

andreasschmieg · Posted: Wed Oct 07, 2015 5:10 pm Post subject:

Excellent thread indeed.
Here is what mine looks like:

Image may have been reduced in size. Click image to view fullscreen.

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~~~ Dont trust cars under 30! ~~~

Maxoceanblue · Posted: Wed Oct 07, 2015 5:49 pm Post subject:

Wouldn't it be better to have the car in neutral and parking brake off? So the drive shaft can rotate as it slides into the engine. Did you use a clutch alignment tool?
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1964 Beetle Sedan/1600cc DP 12v converted

andreasschmieg · Posted: Wed Oct 07, 2015 5:56 pm Post subject:

Maybe I should use some KY. :-)
_________________
~~~ Dont trust cars under 30! ~~~

Bruce · Posted: Wed Oct 07, 2015 9:13 pm Post subject:

KTPhil · Posted: Thu Oct 08, 2015 9:19 am Post subject:

yammi450 · Posted: Thu Oct 08, 2015 8:44 pm Post subject:

I once had a aftermarket HD shaft from EmpI that was welded wrong, and it would hold the throw out bearing to far out and wouldn't allow the engine to mate up to the tranny all the way.

bluebus86 · Banned Joined: September 02, 2010 Posts: 11075

if that is gear oil on the bell housing then you got a tranny leak, fit it before installing the engine or the clutch will be ruined in short order. you may need a new seal at the tranny input shaft.

and the shaft needs to be cleaned up and rust removed. a bearing rides on the end of that shaft, the bearing wont last long with all that rust.
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Dougy Dee · Posted: Fri Oct 09, 2015 6:09 am Post subject:

I had a similar problem several years ago. turns out the new bolts I installed with the new motor mounts were a mm too long and fouled the flywheel. Took a while to find... Bugger!

Dr OnHolliday · Posted: Fri Oct 09, 2015 7:22 am Post subject:

I hope that ghetto rebuild works out for you.
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1965 Type 1 sunroof Baja / about 70k miles on self-rebuilt '74 1600 and counting / SP heads and aftermarket valve keepers / non-doghouse shroud with external cooler and filter / 1.5 qt extended sump / Weber 32/36 DFAV progressive carb / 009 dist with Pertronix / 1.25 ratio rockers and ball adjusters / 1.5" stainless steel J-pipes and carbon steel baja exhaust

andreasschmieg · Posted: Sat Oct 10, 2015 4:03 pm Post subject:

The engine is in now and cranking over. It is a good day.
_________________
~~~ Dont trust cars under 30! ~~~

grandpa pete · Posted: Sat Oct 10, 2015 4:15 pm Post subject:

Tell what you found so you can help the next guy ;please
_________________
63 two fold rag
66 sedan delivery Type 6

http://www.thesamba.com/vw/forum/viewtopic.php?t=569619&highlight=sedan+delivery

andreasschmieg · Posted: Sat Oct 10, 2015 4:50 pm Post subject:

What worked: I cleaned and greased the transmission shaft as suggested above. Used very little grease, so it doesn't smear all over the clutch.

Then I mounted the clutch and cover plate on an identical flywheel that was not attached to an engine. 20 pounds are a lot less than 240 pounds. Once the flywheel and clutch assembly fit all the way in, I put the clutch and clutch cover back on the engine.

Then I used three car jacks to lift the engine in place. Two little ones on each side of a plywood board to lift it up, and a big one to tip it. I stood there in disbelief when it slid right in.

I hooked up the battery and got it cranking over nicely. That also fills all the oil galleys. I will leave the rest of the hookup, timing, and tuneup to my local shop.
_________________
~~~ Dont trust cars under 30! ~~~

Jerome Bosch · Posted: Sat Jul 05, 2025 2:00 am Post subject:

Cusser · Posted: Sat Jul 05, 2025 7:32 am Post subject:


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