Clutch GRINDING BADD after new one installed

[RedEyeBanDiT]

I put a XTD stage 4 6 puck clutch Ebay CLUTCH, it has a 2300lb pressure plate (not real stage 4) goin in my 90 tsi awd. everything went good. except where the clutch sits on the transmission output shaft it doesnt slide right on. it goes on tough and doesnt slide right on like the old one. so when i put the tranny up to the motor, i cannont push the bellhousing all the way to the motor, it is a finger width away. to get i there i have to tighten the bellhousing bolts.

The first time, it grinded bad i couldnt get the car into gear at all. I then put the car into gear with the car OFF then started it and i couldnt get it out of gear.
The second time i did everything over again. HOwever when i installed the clutch, i turned the transfer case when it was in gear and everything turned over motor and tranny. then had some1 push in the clutch and you could feel the clutch spin much easier.

The results of the second time. everything went togheth alittle easier. Now i can get the car into gear but it grinds alil each time and a few times i got it into gear without it grinding, I havent driven it yet.

I checked the slave cylinder and watched it push my shift fork all the way to the bellhousing.

The only thing i can think of is that the clutch disk where it sits on the shaft. The inside of the grooves need to be filed down so the clutch disk slides easily onto the tranny shaft.

If you read that all thank you and what are your recommendations???

 

[boosting_laser]

Put your old clutch back on to check if you're still having problems. If not, then you bought a bad clutch. Some advice: Never install the tranny by forcing it in w/ bolts. That's a recipe for breaking the bell housing. Also filling down the splines on the clutch disc tells you it's no good. Good luck and let us know how things turned out.

 

[jemsoccer]

The reason it went on easier the 2nd time around was because you shaved off a few thousandths when you cranked it down tight w/ the bolts. My guess is that the clutch is not dis-engaging because it is too tight on the shaft. (Which it seems like you have already guessed). I would email the people you bought it from and try to get a new one or a refund. Something as important as a clutch, I would never get off ebay. But, my suggestion w/ that one, if you have to keep it, would be to attempt to slide it on and off of the shaft w/out the tranny attached to it. I'm sure its going to be a tight fit. So, again, if you're stuck w/ it, I would try to shave a few thousandths more off each spline on the clutch. File a couple times, move to the next one until they have all been filed slightly, then test it on the output shaft. Then do it again till it slides perfectly. Make sure to file each one the same amount of times w/ the same pressure, don't want to get things uneven and have any play in there. Good Luck!!

 

[RedEyeBanDiT]

Allrite thanks alot. I did it last nite. filed the shit outta of it till it ran smooth on the shaft of the tranny. the tranny then fit right against the motor with out using the bellhousing bolts to squeeze it together. It works fine now. Thanks alot ppl for the replies. EBAY CLUTCH BUYERS BEWARE!!

 

[99gst_racer]

FYI: Clutches don't "grind", but transmissions can.