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Author Topic: Play in the Intermediate Shaft  (Read 4332 times)

Reply #60June 01, 2018, 04:18:26 pm

fatmobile

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Re: Play in the Intermediate Shaft
« Reply #60 on: June 01, 2018, 04:18:26 pm »
The crank on a 1.6 will hit the I-shaft if it's the one that doesn't have the taper cut off the gear.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #61June 01, 2018, 04:43:02 pm

absenth

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Re: Play in the Intermediate Shaft
« Reply #61 on: June 01, 2018, 04:43:02 pm »
The crank on a 1.6 will hit the I-shaft if it's the one that doesn't have the taper cut off the gear.
Thanks for reminding me about that. I havenít removed the crank yet. Iíll put the larger Shaft in and see if the crank hits it.


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Reply #62June 02, 2018, 02:15:52 pm

absenth

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Re: Play in the Intermediate Shaft
« Reply #62 on: June 02, 2018, 02:15:52 pm »
The crank on a 1.6 will hit the I-shaft if it's the one that doesn't have the taper cut off the gear.

Both shafts worked. I have what I need for the rebuild. I was hoping to find something definitive regarding the I-shafts, 1.5 vs 1.6, gear size etc.




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Reply #63August 07, 2018, 12:54:41 am

fatmobile

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Re: Play in the Intermediate Shaft
« Reply #63 on: August 07, 2018, 12:54:41 am »
Both shafts had the taper cutoff the gear?

Or teeth the full length of the gear?
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #64August 07, 2018, 07:08:42 pm

absenth

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Re: Play in the Intermediate Shaft
« Reply #64 on: August 07, 2018, 07:08:42 pm »
Both shafts had the taper cutoff the gear?

Or teeth the full length of the gear?


By ďtaper cutoffĒ do you mean how the gear on the left is tapered toward the shaft?

Both of these had no problem with the crank clearing them. The gear end on the right stuck past the vacuum pump gear unnecessarily.

I thought the shaft from the 1.5 was not tapered (or less tapered) toward the gear end, and that is where the 1.6 crank could contact somewhere close to the gear end?

Iíve read many, many threads but couldnít find a definitive answer.




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Reply #65August 07, 2018, 10:48:22 pm

fatmobile

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Re: Play in the Intermediate Shaft
« Reply #65 on: August 07, 2018, 10:48:22 pm »
 My buddy got a shaft like the one on the right,.. and after install he couldn't turn the crank because it hit the I-shaft.
  Did you take a look to see how close the crank goes to the I-shaft.?
 Sure it's not 1.5 guts in a 1.6 block right?
 
  Those gears can be pressed off
and with heat on the gear and a frozen shaft they go right back on.
 So you can even use a gasser I-shaft,.. that has the reversed gear.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #66August 07, 2018, 11:20:04 pm

absenth

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Re: Play in the Intermediate Shaft
« Reply #66 on: August 07, 2018, 11:20:04 pm »
My buddy got a shaft like the one on the right,.. and after install he couldn't turn the crank because it hit the I-shaft.
  Did you take a look to see how close the crank goes to the I-shaft.?
 Sure it's not 1.5 guts in a 1.6 block right?
 
  Those gears can be pressed off
and with heat on the gear and a frozen shaft they go right back on.
 So you can even use a gasser I-shaft,.. that has the reversed gear.

I put my finger between the crank and shaft/gear at the closest point in rotation IIRC.

I havenít considered if the internals were swapped. The I shaft with the broken flange had the smaller type gear end. I suppose I could measure the crank journals. Iíll have to find the thread with the differences. Something like 44 vs 46?

Is this you here talking about your buddy? https://www.vwdieselparts.com/forum/viewtopic.php?t=10397


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Reply #67August 08, 2018, 03:24:43 pm

absenth

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Re: Play in the Intermediate Shaft
« Reply #67 on: August 08, 2018, 03:24:43 pm »
My buddy got a shaft like the one on the right,.. and after install he couldn't turn the crank because it hit the I-shaft.
  Did you take a look to see how close the crank goes to the I-shaft.?
 Sure it's not 1.5 guts in a 1.6 block right?
 
  Those gears can be pressed off
and with heat on the gear and a frozen shaft they go right back on.
 So you can even use a gasser I-shaft,.. that has the reversed gear.

I put my finger between the crank and shaft/gear at the closest point in rotation IIRC.

I havenít considered if the internals were swapped. The I shaft with the broken flange had the smaller type gear end. I suppose I could measure the crank journals. Iíll have to find the thread with the differences. Something like 44 vs 46?

Is this you here talking about your buddy? https://www.vwdieselparts.com/forum/viewtopic.php?t=10397


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My Crank Rod Journals measure 47.8mm.

Reply #68August 09, 2018, 12:10:07 am

fatmobile

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Re: Play in the Intermediate Shaft
« Reply #68 on: August 09, 2018, 12:10:07 am »
 Yep that's my post.
 I never saw the crank hit the gear but he's a good mechanic and  said it did
 and after I sold him one with the cut gear it worked fine.

 That's the size of the 1.6 rod journals.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #69August 09, 2018, 10:10:13 am

absenth

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Play in the Intermediate Shaft
« Reply #69 on: August 09, 2018, 10:10:13 am »
Yep that's my post.
 I never saw the crank hit the gear but he's a good mechanic and  said it did
 and after I sold him one with the cut gear it worked fine.

 That's the size of the 1.6 rod journals.

Thanks for confirming the journal size. I placed my crankshaft and the larger uncut gear back in the block. There is space to fit my finger tip between the Throw and the gear. But I donít think that is where the impact would occur. By doing this I now believe the rod or rod cap would be the culprit.

Once I reassemble my engine Iíll throw the suspected 1.5 I-shaft in and Iíll see if I can get a clear picture of the contact.

Thanks for your help.



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« Last Edit: August 10, 2018, 08:06:32 pm by absenth »

Reply #70August 14, 2018, 12:53:34 am

fatmobile

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Re: Play in the Intermediate Shaft
« Reply #70 on: August 14, 2018, 12:53:34 am »
I said it wrong too,.. it wouldn't have been the crank that hit the gear.
  He never removed the rods so it would have been one of them that hit.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

Reply #71August 25, 2018, 04:39:06 pm

absenth

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Re: Play in the Intermediate Shaft
« Reply #71 on: August 25, 2018, 04:39:06 pm »
Another way you can check for straightness is to unbolt the cam, remove the followers and see how much the cam rocks.
 Since you already know how warped your head is, this would be a good chance to try that and calibrate yourself to what a warped head cam rocks like.
 Your head doesn't look like it's been surfaced before.

What tool, besides my eyes, should I use for the cam rock check?


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Reply #72August 25, 2018, 11:42:44 pm

fatmobile

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Re: Play in the Intermediate Shaft
« Reply #72 on: August 25, 2018, 11:42:44 pm »
 It's by feel.
 Feel how much it rocks.
Tornado red, '91 Golf 4 door,
with a re-ringed, '84 quantum, turbo diesel, MD block

 

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