Fixed I hope - transmission, differential won't go back together

[jwallis]

I have the two halves together, hopefully correctly. Thank you very much to everyone who jumped in.

-------original message:--------


I've been trying wrestle these two back together for about three hours now. first on a flat plane now but using a hoist the way Bentley says to do it, transmission on the bottom.

It is extremely close just about to hit the O-ring on the outside with the yellow stripe. It is a hard stop. and when I separate them again there is a little bit of flake looks like brass.

Is there some trick does the transmission need to be in neutral or something like that?

Any help is greatly appreciated. I am about to lose it.
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[jwallis]

is the outer shaft here supposed to spin? maybe it's not mating with the splines in the transmission? That's what I'm guessing that I cannot get that shaft to turn[/img]
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[IdahoDoug]

I just went out to look at my spare trans. I cannot turn the outer shaft, either. However, the inner shaft of mine does not stick out like yours does. It is pretty much flush with the larger shaft. So, perhaps someone else can weigh in on the position of that inner splined shaft. I also assume you have the solid shaft that goes inside the inner splined shaft out of the picture for some reason?

PS - that big chain may be part of your problem....heh....
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1993 Toyota LandCruiser, 2002 BMW 325iX, 1982 Toyota Sunrader

[jwallis]

Good question about the chain but it's not exerting any lateral force. That interior shaft is loose, so it would not prevent mating...
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50+ YouTube videos - brakes, bearings, CV joints, 1.9/2.1 cooling system, mods, Bostig and more...

[IdahoDoug]

Actually I was joking that the chain is laying across the mating surface = no way it's mating.

So, the inner shaft - does it easily move until its flush? And what about my question about the solid inner, inner shaft? Where is yours?
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1987 2WD Wolfsburg Vanagon Weekender "Mango", two fully locked 80 Series LandCruisers. 2017 Subaru Outback boxer. 1990 Audi 90 Quattro 20V with rear locking differential, 1990 burgundy parts Vanagon. 1984 Porsche 944, 1993 Toyota LandCruiser, 2002 BMW 325iX, 1982 Toyota Sunrader

[jwallis]

oh I didn't see that question - that shaft is out because it will just fall out if you hold the differential vertical
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[jwallis]

Just to be real clear about that picture that's the side that goes to the engine.

The inner shaft in the picture is basically loose as well but it will not fall out. I was planning on getting the mated and then seating that one
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50+ YouTube videos - brakes, bearings, CV joints, 1.9/2.1 cooling system, mods, Bostig and more...

[kourt]

Howdy,

If you can't get it together by Sunday, PM me and I'll come over and have a look. Two heads are better than one. I've mated diff+tranny about six times so I have some experience. Have a beer chilled for me.

BTW see this post:

http://www.thesamba.com/vw/forum/viewtopic.php?p=7989275&highlight=#7989275

Looks like your turbine shaft is out too far. Read farther down in that thread for help on how to seat it.

kourt

[AtlasShrugged]

That center shaft should be able to spin while the trans and diff are put together.

As I recall..you need to turn that center shaft to help the assembly go together..don't leave it till after the final assembly..it needs to be installed and ready to go to help spin the automatic transmission while you connect the diff.

[jwallis]

[jwallis]

[jwallis]

I guess my main question is - is there a trick? It's not sounding like it and I would not expect there to be one. It def sounds like a solid THONK when I get very close. The housings just barely overlap.

I'm guessing that forcing it is both a bad idea and impossible (due to the solidness of the blockage).

thanks again. i probably haven't been this frustrated since I did the fuel lines 4 years ago.
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[fraggle00]

Are you sure the middle hollow shaft is in correctly? It can be flopped in backwards and things barely do/don't fit. I know because I did that, made it fit, and later regretted it.
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'91 Vanagon Carat
'87 Porsche 928S4 DOWN
'12 Fiat 500 Abarth

[alaskadan]

Just went through this a few weeks ago. IIRC the inner shaft had slid out and i was able to grab the end of it and jiggle it whilst twisting and pushing and got the inner end to line up and it slid in .

[jwallis]

[jwallis]

[MarkWard]

In the bellhousing, the outer splined piece is the stator support and is fixed. It does not come into play until the torque convertor is installed.

Is there a trick? I would suggest looking at 38.5 in the manual. The pinion shaft has splines that need to seat into the automatic clutch drums. While you are trying to mate the pinion shaft to the automatic, grab both cv flanges and turn them together. This will help to align the pinion shaft splines into the drums.

While you are in the manual, in that section, it would be a good idea to measure the final drive endplay. Good luck.

[jwallis]

[Wildthings]

[MarkWard]