Single Mass Flywheel on ABY - PROBLEMS!!!

[Knight Rider S4]

gheezo you are having all the fun ......so did you hit the guy that tightened the bolt ?........hopefully can get it welded up and back on the road soon

[S2central.net]

Man - is that car jinxed or what ?

I've certainly not heard of the dowel problems described here... And when a pair of trusted hands from MarkH doing the job doesn't report such a problem then I can only assume there must be some variance across the years on the blocks and/or bellhousings... Unless as you say, something else got jammed in there when the tightening sequence started.

Suggest you get outside a dozen bottles of your favourite beer and just hope you feel better in the morning. You won't, but it might help you forget for a while

Paul

[Josh-stateside]

He's lucky..

I had this same problem too when I installed the ABY engine into my coupe quattro 7a engine bay. I unfortunately cracked the ABY block but It was welded and haven't had any problems The Dowel sleeves need to be machined down to allow everything to fit snuggly together.

[slow2]

I think Doug Rs2 mentions this dowel sleeve problem in one of his early engine rebuild projects,

hope you get it welded up ok

[mcandmar]

Yep the dowel pins are too long when you remove the spacer, i had to chop mine back 8-10mm. Also i was told the 5speed bolts can be used to mount the gearbox without a spacer.

Did your mechanic not find it odd the gearbox wasn’t sitting flush when doing up the bolts, they must have been really tight to crack the bell housing

[Jamo]

I think Doug Rs2 mentions this dowel sleeve problem in one of his early engine rebuild projects,

hope you get it welded up ok

Dez good to see you posting mate, do you know the link to this thread?

I'd be very interested to see pics of these dowels

I've just been through Marco's stroker thread and he's not mentioned it either when he went to single mass

[Pirvu Eugen]

For ASZ, ARV, AXM 014 301 153 16x12,8
012 301 153 16/22x16
for CGR 01E 301 153 21,5x13
01E 301 153A 24x13
These dimensions I found on ETOS.
Hope this helps!
Eugen

[Mark Halligan]

I've seen this posted here a few times, I remember Josh's pictures of his cracked block well.

I posted about it here
and here , although it would have been more helpful if I had mentioned it in that other link posted above

I know Sal got away without shortening his and it left a small gap between the block and bell housing.

[Mark Halligan]

Josh's old thread

http://www.s2forum.com/forum/showthread.php?t=662&highlight=cracked

[mcandmar]

Heres a pic from my ABY block...

Mark.

[GT500]

Sorry to here this Andy,
Sounds like mr ham fisted was at work! IF you have to winch the two together then something is wrong!

Bellhousing can be welded easy, nice and thick material.

Make sure mr fist pays for the repair, no excuse for a professional mechanic to make this mistake.

All the best!

[s2_bo]

Andy, So sorry to hear this.

What a PITA.

Keep your chin up. I hope you can sort it in good time..

All the best.
Bo

[Ross]

Andy

It seems you've had a fair bit of bad luck with the S2 recently!! We should start a club

Keep going though, fantastic car and will be worth the wait... do you have a run-around in the mean time?

Cheers
Ross

[Rusty]

In fairness to the guy doing the work (as I was pretty much stood next to him holding the box) he wasn't leaning on the ratchet driver any more than I would have done. It's a shame we found out about the problem in this way rather than everything going tight and there being a gap, bad luick rather than negligence.

I'm going to mod the dowels today and hopefully get the box welded. Should be back together this week if all goes smoothly.

I'll start a new thread about single mass conversion and we can make it a sticky to ensure that all the information is in one place. Might have to be at lunch now.

Anyway, a pic for everyone to wince at:-



And the dowels (ABY left, 7A right):-

[Rusty]

This highlights the difference between CGR and other 'box fixings...