deliriousga

On an '87 S4, I finally got the torque tube out and the new one in, but I'm having a problem at the clutch. The coupler between the short drive shaft that goes through the clutch and the shaft inside the torque tube is not aligning properly. The coupler will slide down the short shaft about 1/2" then it stops. I tried some taps with a screwdriver to see if it was just a little sticky spot, but it still wouldn't move.

Is there some way to align these two shafts so it works properly? When I replaced the clutch before, it slid on very easily.

TIA!

Mrmerlin

OK obvious question is the clamp bolt out of the coupler? It should be.
You may have a nick on one of the splines , is the short shaft in perfect condition? IE no wear marks on it from the clutch discs. If there are wear marks then you may be setting yourself up for a dragging clutch.
try moving the coupler to a different position with the short shaft. put the rear clamp bolt ( transmission)in first so you dont lose the alignment at the trans this will allow you to add a bit more pressure to move things.
Use Hi temp grease or anti seize on the clutch splines. and if your installing the OLD throw out bearing you should consider a new one as the TOB runs all the time at engine speed, since they cant be greased they dont last long

deliriousga

Clamp bolts are out.

Everything is new. I put in a 928 Intl. rebuilt torque tube, clutch, T/O bearing, pilot bearing and short shaft. I checked the short shaft and there are no nicks on the splines.

In the instructions to replace the '87+ torque tube it says to mark where the "shims" are when you unbolt the transmission case, but mine had no shims that I could find anywhere. I'm wondering if that's the problem, but still at a loss.

Vilhuer

No, those can't explain such problems at other end of TT. Do you have small aligning tubes between bellhousing and TT? There should be two IIRR. One on top center and another at bottom center. Sometimes these remain in bellhousing and sometimes in TT when they are taken apart. If your old TT had them both and new one doesn't bellhousing and TT might not align properly.

Mark Anderson

sounds to me like u need to use a long lever and release the clutch so u can realign the short shaft.

deliriousga

Thanks Erkka & Mark. I'm pretty sure the aligning pegs were in there, but I'll check just to make sure. If they're in then I'll try releasing the clutch and see if that helps.

That makes sense because it seems like the last time I did the clutch the short shaft would move up and down a little but this time it's not moving at all. Maybe it just needs to be coaxed a little.

Thanks again!

Mrmerlin

if you have a problem releasing the clutch try loosening the bolts to the P Plate this should let the shafts align properly, then fit the clamp ( collar) and set the short shaft depth and then tighten the PP bolts