Outer Limits 4x4 Board

Help?

Engine almost bak in, but just can't get the engine and transmission back together - driveshaft just isn't joining :(

Any hints? Manual just says ' line them up, bolt them in' - not good enough! 1 hour later I am stufffed and still can't do it :(

Last job for today I think - as soon as I can get this back together I can return the rental hoist and rest until tomorrow to hook all the aux stuff back up........

Drewe

AFAIK you need to align the clutch assy before trying to fit the gearbox.

Clutch itself is assembled to the block (came with ) - I have even tried jacking the gearbox to get 'just the right' angle - won't go on! @#$@#$@#$@#$@##$@#$@#$@#

this is prob to late now. but

like murcod said make sure its aligned (clutch that is) just coz its on there doesnt mean anything, dont just trust peopes work in good fortune. also have a look at the gear box splines if you have been rough with it you may have damaged them if they dammaged use a small file and clean then wack on a bit of grease and should go in just a thought

you wouldnt stick your dick in somthin that was dry would you!! lube her up.

Nah, not too late. Started at 7... By one had collected the hoist, removed old engine, changed over bits from old to new I wanted to keep or needed to change.....

At 1 started trying to 'mate' the spline with the clutch... Have just packed everything away for the night and will try again in the morning! Will get some grease from SuperCr8p and try again :(

REally, got nothing better to do than keep trying - I need to return the hoist at 9ish tomorrow or pay for another day! Oh well.....

When I changed from part time to full time 4WD I had problems getting the tranny in. The pilot shafts are different sizes between the two. I also believe that there are different siz pilot shafts in the different years. My part time tranny took a bearing and the full time took a bushing. The full time had a much smaller pilot shaft than the part time so the part time wouldn't go in no matter what I did...finally figured it out and Mike H. sent me a bearing.

I swapped the trannys and transfer cases out five different times and never had trouble lineing up the splines.

If you have some calipers measure the pilot shaft and the bearing or bushing in the flywheel.

So you changed the clutch yourself? Did you align the friction plate up, or just whack it in. Look through the centre of the pressure plate fingers, and see if its centred. You can also check it around the edge, between the flywheel and pressure plate. Align the edge of the friction plate with the shiny wear area on the flywheel. Lubing the tip and start of the input shaft spline will help too.

You have it easy, only lightish motor/gearbox combination. Try doing it with a Rocky diesel lump, where motor weighs 1/4 tonne, and gearbox is nearly 100kg, then you will know what problems are. Thats exactly the reason I pull the whole motor/gearbox/transfer case assembly out if I am doing clutch work. Much easier to line them up on the floor than in the vehicle.

Thanks for the help guys - All on!

Spent last night looking at pulling the tranny out too, mating on the floor and putting the lot in - decided I would have one more concerted effort, based on experience from the day before and lots of web browsing...

For the uninitiated, here's how I got it done....

Greased up the shaft and splines to make life easier.... (Thanks for the tip - nice, simple, logical and easy not to think of!)

Got them part together (the hard spot) - wiggled, pushed, moaned, etc, all while using shoulder to push, one hand to line up and the other to turn the crankshaft with a ratchet.... Stopped when I heard 'clicking' - the splines were about to mate (sound like David Edinborough..... And the male spline greased up and got ready to.....)

Got the top two bolts to the tranny in, did them up to about half - alternating sides going about half a turn at a time.

Got under the car - bottom was way out - jacked the tranny up slowly till I could get bottom bolt in - as I did this the whole thing 'slipped' together -

Bolted 3/4 up, got the engine mounts in (I did all this with them off to make more room to play), bolted up loosley...

Now coming to watch the F1 qualifying I recorded to recover

@$#@ Hell! This engine better work!

if the tranny is still connected to the driveline of the rear tires, you can jack up the back end and wiggle the back tires back and forth a bit until the tranny slips in a bit, and then once you get resistance, wiggle the tires again and then go back and slide it in some more. its how i got mine in dispite the fact that i had everything lined up. the f$*#er wouldnt go in until i started wiggling the tires a bit.

Dont put grease on the input shaft ! Graphite powder only. My clutch builder says grease on input shafts is the number 1 killer of clutches. And even if ya use graphite powder dont use too much, i've never needed any to be honest.

Cheers!

Ahhh. Well. Too late now!

mmm strange, i've put grease in my input shaft, hasn't a problem ever since.. coz i didn't put too much on, just a bit..say a finger tip much.

Yeah i cant really see it doing that much damage personally. I get my cluthces done by Jim Berry at Raceclutch Italia Spares in Wooloongabba. He mainly does clutches for Race cars so i'd say the margin for error is far less and he would have to deal with all the guys that bring back fucked clutches bitching about his work hehe