Problem I have NEVER encountered
 

I am in the process of helping Jason (porschepolisher of stripped fastener fame) complete his clutch job, and have a problem I have never encountered before. The driveline coupler will not go all the way onto the torque shaft. When you back the coupler onto the transmission input shaft, then slide it back to the "driveshaft", the transmission seems to be lower than the driveline. I can only get the coupler about half way onto the shaft.

Even tried with a prybar, and it still won't go on. The coupler slid onto the driveline and the input shaft just fine before the transmission was installed. Anyone have any ideas?

Maybe put a block of wood under the bellhousing and raise it up a small amount with a jack to make the torque tube level so the coupler will slide on.

tried that, no deal. The transmission is to low, and attempting to raise the trans, only moves the whole chassis up

Were both of the alignment pins installed in the transaxle before you mated it to the TT flange? Sometimes these things fall out.

that's a thought, I know the one on the passenger side was in, I'll have to check for the other. Even if both the pins were not there, the bolt holes line up, as I have run the 3 cap screws in just enough to get them started. But I will check for the alignment pins tomorrow morning. Thanks kdj

As I said, with the trans matd to the TT adapter, it looks like the input shaft is 3 or 4 (possibly more) millimeters below the line created by the driveshaft. They line up close enough that the top of the coupler is just below flush with the top of the actual driveshaft.

I checked the motor mount before transmission was installed, and the mount was secure and actually appeared new. Trans mount support was installed and properly torqued by myself. It's almost like the trans mount itself is to long....like I said, I have NEVER encountered anything like this in the past, and I'd hate to think of how many of these clutches and/or transmissions I have changed over the course of the past umpteen years. lol

perhaps there's a damage/burr on the inside of the coupler, preventing the spline(s) from going past a certain point? or on either shafts?

i used some mobile1 grease on the coupler/shaft to help them slide in.

nope, no burrs, that is why I slid the coupler all the way on BOTH shafts before the install, to make sure that the coupler was ok. As noted above, there is a definate offset between the center of the shaft and the center of the trans input shaft. The driveline is higher than the trans input shaft. Going over there this afternoon, and will tear into it again, remove the trans again (if necessary), and start over. :(

So they don't line up even though the trans is bolted to the torque tube??

Are the 2 bolts COMPLETELY removed from the coupler? It won't go in even if the bolts are only partially threaded into the coupler.

The two bolts are laying under the left tire. The transmission is bolted to the torque tube.

Tomorrow (couldn't make it yesterday or today) I am going to go over and unbolt everything, and see if I can raise the trans just a bit to get the coupler to slide forward. If not, then the trans will come out again and I will put the coupler on the torque tube, raise the trans and then pull the torque tube down and move the coupler onto the input shaft.