Engine/Transmission installation failure

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Engine/Transmission installation failure

Postby Tony46 » Sat Aug 26, 2017 7:06 pm

Subaru EJ25
Rancho transmission
STAGE II clutch

So I finally got around to installing the engine and transmission...with issue of course.
I used the centering tool to align the pressure plate and the clutch disk. After the first attempt at mating the transmission with the engine,
I noticed that the sleave around the transmission spline (where the throwout bearing sits), was scored and binding as if it wasn't entering the centre of the pressure plate. I also noticed that the pressure plate had an uneven lip around the inside circumference. So it looks like its binding when installed.
Whats the fix here...can I remove that sleave on the transmission spline and grind it smooth, doing the same with the pressure plate? Or have I somehow damaged these parts and need to replace them?

I also noticed that the kennedy adaptor plate come with a longer stud to install top left of the plate for the starter. This bolt barely bolts onto the transmission...seems short to get at starter attached as well. Is this normal?
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Re: Engine/Transmission installation failure

Postby Tony46 » Mon Aug 28, 2017 3:43 am

So it looks like the throwout bearing guide tube is slightly bent around the rim. The Throw out bearing still slides freely. If I file the guide tube rim smooth again and maybe shorten the length by 1/8", will this negativly affect the clutch function?
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Re: Engine/Transmission installation failure

Postby sjgharib » Mon Aug 28, 2017 11:17 am

I have a similar setup, but I honestly don't recall having any issues...

Can you post some pictures?
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Re: Engine/Transmission installation failure

Postby EEricson » Mon Aug 28, 2017 6:33 pm

I think the sleeve thingy has to go.

There were two different sized throwout bearings in the VWs. The early ones used the sleeve to center the bearing, and later ones did not. If you use the sleeve with the later bearing, you get this binding thing.

(Or something like that...not fully remembering the details).

I do remember something very similar happening to me when I first put the Subaru engine on the Kennedy Adaptor on the t1 transaxle. I put it together at least twice before I caught the mistake.

Hope this helps.
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Re: Engine/Transmission installation failure

Postby Tony46 » Mon Aug 28, 2017 8:34 pm

[img]<a%20href="http://s1356.photobucket.com/user/b9406/media/20170828_220745_zpsduhcqw7d.jpg.html"%20target="_blank"><img%20src="http://i1356.photobucket.com/albums/q721/b9406/20170828_220745_zpsduhcqw7d.jpg"%20border="0"%20alt="%20photo%2020170828_220745_zpsduhcqw7d.jpg"/></a>[/img]

Here is a picture of the throwout bearing on its guide. Does this style bearing require the guide? Does the guide serve any other purpose than to guide the Throw out? Or can I shave down the kink?
Last edited by Tony46 on Tue Aug 29, 2017 2:41 pm, edited 1 time in total.
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Re: Engine/Transmission installation failure

Postby Tony46 » Tue Aug 29, 2017 3:31 am

EEricson wrote:I think the sleeve thingy has to go.


So...EEricson got me reading. Looks like I have the newer style Throw out bearing which from what I'm reading means ibhave to remove a centering ring from the pressure plate. Going to take it apart and see what this centering ring is all about
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Re: Engine/Transmission installation failure

Postby EEricson » Tue Aug 29, 2017 6:30 am

I remember it being obvious once I realized the mistake. I wish my mind were more detail-oriented so I could describe this more fully.
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Re: Engine/Transmission installation failure

Postby Tony46 » Tue Aug 29, 2017 8:12 am

It worked out. I removed the centering ring from the pressure plate and it all went together well.
But it looks like I will need to take it apart again because i don't see how the starter bolt is long enough
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Re: Engine/Transmission installation failure

Postby DannyP » Tue Aug 29, 2017 4:19 pm

Yeah the old style throwout bearing has two pins that rest in the clutch arm/fork and requires spring clips to hold in place. The new style is 1971 or 73 and up.

Just cut te short one and get a longer bolt and put the bolt through the starter and put the nut on engine side.
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