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TR2/3/3A putting the sleeves into the block

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sp53

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Well I was putting the sleeves into the block and I cannot get # 3 to go down the last 1/32. The others go down fine, but #3 hits something. I tried another sleeve but no joy, so the problem is at the #3 point. I check and cleaned everything and I cannot see what it is hitting. I am soaking an old sleeve because it was cruddy to see if the problem is in the aftermarket sleeves. I feel pretty foolish for not trying the sleeves in the block before I put the crank and seal in because this does not look good. Perhaps the block is cracked or something. The only thing I can think is there is a casting web right at that point and perhaps the sleeve is hitting that, sighed Mayday.
 
Number 3 is adjacent to the block drain hole, which is a source of scale. I also had to clean hard scale from the seal ledge for every hole. This hard scale was so hard I had to use a chisel and hammer to break it off. It looked just like casting flash. The original sleeves were machined just a bit differently than the replacements. The hard scale builds on the seal ledge where the flat faces were machined into the sleeves. If the new sleeve flats are even a coupe hundredths different, that would be enough to stop the sleeve.

Guess that's a long winded suggestion to look for scale on the seal ledge that looks like flash...
 
Thanks John I will double check the perimeter. You’re thinking the actual lugs on the side of the sleeve are hitting a protrusion. Here a shot of the water jacket. One is after I cleaned it with acid, and the other is cleaned, but with no acid. I can hear it hit, but I cannot see the exact spot. My camera is not the best, so the detail is vague.
 

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I had mine hot tanked, and my machine shop guy said he worked on it with a wire wheel. I still had to go after that ledge with a chisel, though. You would swear the scale was cast into the block, but the chunks would chip off pretty easily once you got a good angle on them. That's really my only idea about why it won't go in all the way. Maybe some of the experienced guys know of other gotcha's...
 
The good news is the 83mm sleeve slid right in, so the problem are the aftermarket sleeves. I think I found where and why it is hitting, but it is not totally conclusive because I could not see any witness marks. I tried painting with a marker and I think I see a spot where it is hitting. I need a red marker. Anyway the aftermarket sleeves do not have the same tapper on the bottom edge as the OE. The aftermarket ones are almost cut square and the bottom and are hitting that webbing in the cast between 2&3. I am think I will take a grinder and bevel the sleeve back some, but if that sounds wrong, someone please chime in.
 
I agree -- seems like a reasonable approach.

My sleeves came from Moss and I decided to give them one try w/o any trial fitting -- just put on the Permatex Aviation Gasket Sealer on the FO8s and dropped them in. I was lucky as they fit perfectly and sat proud of the block all the way around.
 
I used a wire brush on mine (on the end of a drill extension), and also used a chisel to chip away the rust. I don't know really, but I think I might stuff some cling wrap down there, and see if you can't make a tear where it's bottoming out? It may not be a good idea, but it's the only one I have... good luck.
 
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