I swapped in a new shortstar this weekend, after getting the old engine off, we inspected the clutch and put in a new throwout bearing and a new pressure plate. We had a real difficult time getting engine/clutch lined up with transaxle it was the last 1/2 inch that was a bear. Finally got it in, got everything hooked up, engine fired right up. Problem is the clutch isn't working, push it to the floor and it doesn't disengage the motor at all from the tranny.

Tried adjusting the clutch, bleeding the clutch but problem still persists? It's a shortstar mated to a Mendi E box, 200MM double disc clutch with a VW spline?

Looks like I'll be taking the engine off again, any suggestions on what to look for in the clutch?

All I can think of is that the disc is in backwards, the flat side should go to the flywheel. Other thing is pilot bearing but it should be the same as the old engine since it is on the flywheel.

Yep, flywheel/pilot bearing are the same. Will be checking clutch discs when I get it out. Any hints on getting it lined up/installed on engine?

As long as you are using an alignment tool it should be pretty easy. NEVER pull the last bit in with a bolt though it will ruin the disc.

Anybody know the best place to get an alignment tool in Phoenix? Do I need to know anything other than I have VW splines? I have a dual disc clutch, does a dual disc clutch require a longer tool?

Bap parts, Karls, the shaft should be the same even with dual discs. I have one you can borrow but I am on the east side. Teh assembly with dual discs is different but you should be able to figure it out by looking.

Bill at Arizona Transaxle should have them. 30th ave and Indian School.

Did some research on this site and the only other people with this issue have had bad pressure plates. See:

http://www.glamisdunes.com/invision/index....showtopic=54800

I bought a new Kennedy Stage 3 dual disc pressure plate but is there anyway to test a pressure plate?

What was on it before?

If you don't have a clutch alignment tool use a broom handle shaved too a point.
The hardest part about getting the engine and tranny lined up properly is the shaft splines, I put the trans in gear, then if the trans doesn't slide in freeley, I rotate the cv's or driveshaft, then try again, I repeat the process if it doesn't work.
It usually goes in on the first couple of tries.

I replaced the existing pressure plate with the same one, Kennedy stage 3 dual disc. Any tests I should run before putting it all completely back together?

I had this problem with my old car. I R&R'd the motor twice before I finally tried a different pressure plate. Im willing to bet you have the same problem. Your symptoms are exactly what mine were.

If you want you can give us a call at the shop and we can talk you through how test the plate for release and to make sure it works before even putting the thing in the car. That way atleast you know what the problem could be or if it is not a problem at all.