Project Black Golfball-plans for 2010 Options

[black92_tsi_awd]

Finally got back to working on the Talon Sat.

After I put in the replacement trans, I developed a leak and parked the car again due to the weather. I thought it was the transfer case seal so I pulled it out. Transfer Case was full of oil, so that wasn't it.

The inside on the trans housing was all wet when I pulled the clutch fork boot off so apparently one of the trans seals is leaking. Looks like the output shaft for the transfer case may be the culprit. It seems to be seaping just sitting in the driveway. Thing is, why would it be wet up by the clutch fork?? The input shaft seal shouldn't be leaking that much because it's above the oil line in the trans, at least I think so. I hope it's not the input shaft seal, I'd have to disaasemble the trans to replace that.

I did remove the inoperable cruise control since I picked up a no-cruise cable over the winter. Need to finish hooking that stuff up.

[black92_tsi_awd]

Well spent 7 hours getting everything together...no joy, clutch won't fully disengage!
Had a hell of a time get the trans in. Stripped out one of the top trans bolt. Ended up putting ez-threads in both holes.
Bled the clutch system.
Made some extended clutch rods. The last rod is just long enough not to pre-load the clutch fingers witht the TOB.
It will only go into 1st and 2nd and barely disengages 1/4" off the floor.

The flywheel was checked and it's step height was .61" It's a brand new ACT 2600 clutch and disk and MITSU TOB. You would think that with all new componant and the same shimmed shift fork as before it would have plenty of fork movement.

I guess I can shim the fork ball some more...don't know what else to do.