Tranny wont go back in!!!!

[Matrix_Blue]

me and my buddy changed the clutch in a 90 tsi awd. it came out easy of course but the stupid thing wont go back on!!! we have tried evrything i can think of , so if any one has any suggestions about how to do it then it would be greatly appreciated, i have never had this much of a problem doing a clutch and i have done quite a few so please any one help.


Thanks, Ben

 

[TurboDSM90]

Pull off the clutch again. Double check to make sure you have the right clutch disk(attempt to put the disk on the splines). Make sure it goes in and out easily/smoothly.

While tightening the pressure plate onto the flywheel, make sure the allignment tool slides in and out smoothly while tightening the pressure plate(in a circular motion of course).

I usually start with the pressure plate on with all the bolts in position, screwed in about 1 turn, then pull the clutch alignment tool up just a hair and hold it. This fights gravity a little bit, and ensures the clutch disc is nicely centered(Visualize it). I then start tightening the pressure plate bolts, about 3/4 of a turn each, in a circular motion.

Also make sure the dowels are clear to go in. They might have got loose around there, and might be crooked. You said you were just changing the clutch so this might not apply.


Anywho, good luck, and let us know what the problem was

 

[Raph]

u seemed to have covered it all i recently did the clutch on my winter beater without an alignment tool..that was a bi***! (i used a 6mm long socket..and put electrical tape aound it till it fit(7mm was too thick) Ghetto fabed an Alignment tool YEAH

 

[Matrix_Blue]

I just cant get the tranny up to meet the block so that is where i am stuck I know it sounds stupid but i dont know any other way unless i drop the engine mounts and let the tranny and the engine meet at an angle. There is only one problem with that though, it came out sorta easy but it doesnt wanna go in easy, with or without a tranny jack, i just got fed up with it and seft it alone for the night, but the clutch is aligned and all it just wont let the output shaft for the awd fit so we can rotate it into place. i know im babbling but i am just a little frustrated sorry.

Thanks again, Ben

 

[92redman]

Man there is something wrong if you can't get the tranny in w/ two people. I put my tranny in by myself hanging over the fender of the car with no problem.

You gotta make sure that the disk is lined up and the when you get the tranny lined up, rotate it back and forth until you get the splines to line up with the disk and slide it in place. If the input shaft will not go into the disk, I would pull the disk back off and try sliding it on the input shaft to make sure it's the correct splines.

 

[TurboDSM90]

I just cant get the tranny up to meet the block so that is where i am stuck I know it sounds stupid but i dont know any other way unless i drop the engine mounts and let the tranny and the engine meet at an angle. There is only one problem with that though, it came out sorta easy but it doesnt wanna go in easy, with or without a tranny jack, i just got fed up with it and seft it alone for the night, but the clutch is aligned and all it just wont let the output shaft for the awd fit so we can rotate it into place. i know im babbling but i am just a little frustrated sorry.

Thanks again, Ben

Hmm...So you are saying that you havent even had the tranny touch the block yet? It doesn't seem to go in all the way? If so, I believe you have gotten to the bermuda triangle of installing a tranny. There is a small lip hanging over blocking the tranny from going in. This lip is on the crossmember where the steering rack is. The tranny will not go straight in. It has to go up, rotated in a certain direction then once it looks like its close, you rotate the whole tranny (clockwise if looking at it from the passengers wheel well). It should then need a lift up and in.

From what it sounds like, the tranny is hitting that lip in the rear. Either that or you didn't take off that triangular gusset. But i dont believe you can really pull off the tranny without removing it.

I hope you have looked at the vfaq on this? located here

I might be off. If I am- refer to the vfaq.

 

[bigfoot]

turbodsm90 just described the fun time I had with mine. I was by myself but I used a comealong to take the weight while I wrestled it in. Make sure nothing gets in between like that little bracket that holds some wiring on top. Enjoy, with AWD we go through clutches pretty fast so just think of this as practice.

 

[sinfire55]

You guys should try putting an EVO tranny back in. There were 4 of us and it took us 2 1/2 hours. The crossmember is a major obstacle and the thing weighs a ton.

Made me realize that if(when) I get an EVO, I'm just gonna pay someone else to R & R it.