HELP! tranny not same?

[foreverinvayne]

I need help. I bought a used tranny online a couple weeks back and i finally got it put in my 90 TSI AWD. everything about the tranny looked EXACTLY like my old one so I didn't think anything ofi t since the guy told me it was thesame tranny from the same year and everything. Well, I don't know if we're just aligning it wrong or what but the transfer case doesn't seem to want to fit on it. We'll try again tomorrow but i would like to know if there are any differences people could tell me between the 90 awd tranny and the other years.

So PLEASE anyone help me out if you can. Cuz I'm just hoping it's simply us not lining it up right or what. (and yes, we tried spinning the axles to cause the splines to move to fit better, so don't go suggesting that )

 

[Slipstream]

Count the splines they all look the same on the outside.
roughly the mid91-99 is a 23 spline and the 89-mid91 is a 22 spline..iirc
Likely the chap you bought it off of was mistaken.

 

[foreverinvayne]

here's the real question tho.... will everything be fine if i just get a 23 spline transfer case? cuz EVERYTHING is the same and fits perfect.

 

[Slipstream]

Assuming that it is a problem with spline count then yes changing to the appropriate tx case for the new tranny will alleviate the problem.

 

[foreverinvayne]

It's just that i've read that you need to change the shifter assembly on a 90 to make it fit... maybe I misread it or whatever, but my biggest concern is how much work and money I'm gonna have to fork over to fix it. Cuz if it's just a transfer case hopefully i can get one cheap and fast and bolt it on... but if i have to change more, then i'll be VERY mad.

 

[Slipstream]

It's just that i've read that you need to change the shifter assembly on a 90 to make it fit... maybe I misread it or whatever, but my biggest concern is how much work and money I'm gonna have to fork over to fix it. Cuz if it's just a transfer case hopefully i can get one cheap and fast and bolt it on... but if i have to change more, then i'll be VERY mad.

Odds are that if it is a spline problem, it is a later year tranny. Besides picking up a later year tx case you'll need to change the shifter linkage...it's been a very long time since I've had to swap a tranny in a 1g so I'm doing the best I can with my senile mind.

http://dsmtuners.com/forums/showthread.php?t=93739
http://dsmtuners.com/forums/showthread.php?t=150568
http://dsmtuners.com/forums/showthread.php?t=155911
http://dsmtuners.com/forums/showthread.php?t=157720

There are some helpful threads. Depending on your situation I would probably return the tranny letting them know that it was the incorrect year for your car and pick up the right tranny...that would solve all the problems, be the easiest and cheapest. If you are stuck with this tranny or just need to make it work, I'd start hunting around for the right shifter assembly, cables, etc.

But again, and I can't stress this enough...make sure it is a spline count problem that we're dealing with, otherwise this is all a moot point.

 

[foreverinvayne]

okay... now the strangest developments have come forth. I measured both of the shift control arm pieces on the old tranny and the new tranny. THEY ARE EXACTLY THE SAME. (and no, i didn't measure the interchangeable piece, because i had to take it off my old tranny for the new one) They both measure exactly the same. So if that's fine i won't have to worry about the shifting.

Did they EVER make a 23 spline tranny in 90 at all? Because the guy I bought it from swears up and down that it's from his 90 TSI. I have counted the splines on it more than once already and I'm pretty sure it's 23. (of course it's very difficult to get my head in there to see very well now that the tranny is hooked up in my car)

This whole situation is very confusing that's all... The only other explanation I can think of is that someone rebuilt this tranny and had to use later model parts... but that wouldn't explain how he also had a 23 spline transfer case on it too... That is unless he bought it used and didn't know something was done to the car before he had it. GRRR!