Vigilante converter problem
 

This afternoon I attempted to install my engine and transmission into my car. However, I ran into a snag. The snout on my torque converter, PI Vigilante, is not fitting well into the receiving end of the crankshaft. In the past, I remember always seating the torque converter to the trans pump, installing the transmission, tightening the trans bolts to the engine completely and then very easily easing the converter back to mate up to the flexplate installing the bolts there. This time, I install the trans to the motor, tighten all the trans to motor bolts compltely and then try to pull the converter to the flexplate to tighten those bolts, but the converter just will not fit into the crankshaft. The transmission seats completely against the motor, so no interference there. The converter is seating completely to the trans pump. It spins easily until I go to try and tighten the converter to flexplate bolts.

I pulled it all back apart and try to put the converter snout into the crankshaft. I was not able to get it to fully go into the crankshaft. Here's the problem, I got out the calipers and measured the hole of the crankshaft and got a measurement of 1.704. I measured the converter snout and got 1.708. I then checked the snout for burs. I felt a small lip there so I got out the file and smoothed it up, still would not fit. I then got out some emery cloth and began working it around the snout. I did manage to get the converter into the crankshaft hole, but only after I wobbled the converter into the crankshaft. I would not be able to do that once it is installed in the trans and the trans is intalled on the motor. I should be able to, very easily, pull the converter back to the flexplate and install the bolts. Am I going to have to keep going at the snout with emery to get the snout to fit easier in the crankshaft? Or...Am I going to have to take this to a machine shop and have a couple thousands taken off the snout of the converter?

By the way, the converter is the correct converter for the motor. The flexplate is the correct flexplate for the motor and it is installed correctly. Everything is installed correctly, I'm just having an issue of one company is not fitting well with another company. The crank is an Eagle forged crank

it's possible that the crank or converter is mis-machined. Every time I've seen the issue (and they're rare) there is a burr on the crank or converter, or paint on the converter where it meets the crank recess.

The converter had a slight lip on the snout, but my finger nail could not catch it. I went around the circumference of the snout several times with the file and also hit it with emery cloth. The crank didn't have any burrs in it either. The snout is about 3 thousandths larger than the crank. After I filed and emery clothed the converter I could finally get it to fit in the crank, but it took some force and wiggling to get it to seat on the flexplate. All of which, I would not be able to do with the converter installed in the trans. I guess I'm just gonna have to keep at it with the emery cloth:(

I think the difference in measurement is due to the difference in measuring id and od. If the snout of the converter was truly larger than the recess in the crank you would not get it in, wiggling or not.

If it's truly larger you'll probably need it machined.

I never was able to get it in till I used a file on the snout and then emery cloth. I did not take a measurement after I finished with that.