Assembling engine and transmission: Will not sit flush

[redscare]

Hi, I just wanted a second opinion in case I did something wrong. 
I am trying to bolt up the transmission with the engine out of the car.
engine is 1.6d, trans is a new to the car, but a ff 020

I think I have the clutch disc on right, but maybe a second set of eyes cant hurt.

The transmission will not sit flush on the bottom dowel pin.  It sits flat on the top and I can thread in the tops 2 engine bolts, as well as the lower bolt near the axle flange.

But the trans sits about an 1/8" off the block on the front dowel pin.
Any suggestions other than tighten everything down and hope for the best?
here is the setup

It will not sit 100% flush on this pin. binding somewhere.



I found this image from Broke vw, my dimensions match.


 

[8v-of-fury!]

Is it sliding in to the splines in the clutch disk properly? Is the main-shaft of the transmission bent?

If you remove the Flywheel and Disk, will it go on properly then?

[redscare]

I will try it without the flywheel and clutch. The spline doesnt appear bent and I checked the clutch disc on the transmission before I put it together.  Almost done. Just one more little hurdle.

[745 turbogreasel]

Don't force it.

[burn_your_money]

If you pull the dowel out of the engine will it sit flush?

[theman53]

Did you use a clutch alignment tool if you had the pp off?

[8v-of-fury!]

As long as it is centered, it is aligned.

[ORCoaster]

Is the clutch turned around 180 degrees.  I got in a hurry once on a Subaru and ended up getting close like you say and when I started to tighten it down I cracked the housing so go easy on it.  That was one expensive clutch job for me.  I needed it to be towed, welded on and they shop pretty much did the rest for a few bucks.  They made their money on the rest apparently.

[8v-of-fury!]

Looks like it is on right. Do you mean disk? or flywheel?

[ORCoaster]

Disc.  Flywheel is correct.  That only goes on one way.  The disc could be flipped front to back and they splines would go in but hit on the front of the shaft if the disc is backwards.  Follow?

[8v-of-fury!]

I do, previous post saying "Looks like it is on right" I was referring to the clutch disk.

[redscare]

Well the transmission is on. Thank you for the input.  I tried it without the flywheel and it went on ok.  Tried it without the clutch disc and it was ok.  Then tried it again with the flywheel lightly torqued.  After 10 attempts, I think I'm good.  Everything spins freely and axle cups turn over when I select a gear.

[burn_your_money]

Good to hear you got it sorted. It sounds like it was a clutch alignment issue?

You have the flywheel properly torqued right?

[redscare]

Yes flywheel torqued to 15 ft lbs per the bentley.  I think the disc was slightly off center, even though I used the alignment tool.    

Engine is in the car, just doing the cooling system and wiring.  
Will be nice to drive the car again, especially with a 5 speed.
65 mph was 3600 rpm before.
should be 2600 rpm after.

[8v-of-fury!]

The clutch alignment tool doesn't really work.

I find it does not actually center it! lol There is quite a bit of play on either side of the tool, and as you found out.. it didn't center it properly.