[Previologist]

Originally Posted by AuSeeker

Support the back of the engine or it will tilt/drop down once the transmission is no longer there to support it!!!

I do have a wood block on a floor jack under the oil pan. I hope that's enough because I think the tranny is at least partly if not completely free now. I know it budged backwards an inch or so and that's where I left it for dinner. Heading out to survey the situation now...

[AuSeeker]

Originally Posted by Previologist

I do have a wood block on a floor jack under the oil pan. I hope that's enough because I think the tranny is at least partly if not completely free now. I know it budged backwards an inch or so and that's where I left it for dinner. Heading out to survey the situation now...

The jack will be fine for support.

[Previologist]

Well it's out. Phew! And I didn't break a single thing, except maybe the Harbor Freight jack lol. It's looking and acting a bit err, lopsided. Will assess in the morning.

I'd like to think the worst is behind me now, but I know better. It came out really easy, and I know it won't be that easy getting it back in.

[AuSeeker]

Originally Posted by Previologist

Well it's out. Phew! And I didn't break a single thing, except maybe the Harbor Freight jack lol. It's looking and acting a bit err, lopsided. Will assess in the morning.

I'd like to think the worst is behind me now, but I know better. It came out really easy, and I know it won't be that easy getting it back in.

Congratulations!

Do you have a clutch alignment tool to get the clutch in it's proper position when you install it?

[Previologist]

Originally Posted by AuSeeker

Congratulations!

Do you have a clutch alignment tool to get the clutch in it's proper position when you install it?

Yep there's one in the Aisin kit I bought. I didn't realize that until tonight. I was at the auto parts store buying brake cleaner and asked if they had one, and they said it usually comes with their clutch kits. I came home and sho nuff, there it was.

[brillo_76]

Great news. Glad you got it out.. :-)

[phattyduck]

Originally Posted by Previologist

Yep there's one in the Aisin kit I bought. I didn't realize that until tonight. I was at the auto parts store buying brake cleaner and asked if they had one, and they said it usually comes with their clutch kits. I came home and sho nuff, there it was.

Most shops that do a particular transmission regularly will cut the input shaft off a broken trans to use. You'll have to be careful with the plastic too since there is some extra play there. When you put it back together have a *very* light film of grease on the input shaft (like, apply then wipe it off fairly well) and a bit of grease on the dowel pins too to help everything come together.

I have also used extra bellhousing bolts with the head cut off (and a slot cut in place of the head to allow removal) as alignment dowels to help too. You may also have to rotate the trans output shaft (with it in gear) slightly to get the input splines to line up with the clutch.

-Charlie

[Previologist]

Originally Posted by phattyduck

Most shops that do a particular transmission regularly will cut the input shaft off a broken trans to use. You'll have to be careful with the plastic too since there is some extra play there. When you put it back together have a *very* light film of grease on the input shaft (like, apply then wipe it off fairly well) and a bit of grease on the dowel pins too to help everything come together.

What do you mean by "be very careful" with the plastic tool? What am I trying to avoid from happening? I haven't studied the installation process in detail yet, maybe it will be obvious when I do.

I have also used extra bellhousing bolts with the head cut off (and a slot cut in place of the head to allow removal) as alignment dowels to help too. You may also have to rotate the trans output shaft (with it in gear) slightly to get the input splines to line up with the clutch.

-Charlie

Do you install the cut bolts first and use them as extra dowels, or screw them in once you have it close just to tweak the final alignment? I like the idea but might try it once without just to see if I get lucky.

I don't think I'm going to get lucky on the flywheel. I'm no expert but to me it looks like new flywheel time.

[Previologist]

not sure why this wouldn't attach to the post above...

[phattyduck]

Originally Posted by Previologist

What do you mean by "be very careful" with the plastic tool? What am I trying to avoid from happening? I haven't studied the installation process in detail yet, maybe it will be obvious when I do.

The plastic tool has much larger clearances, so you can use the 'alignment tool' and still be misaligned and have assembly issues. You can also damage the plastic if you aren't careful. Make sure you are careful to not damage it and make sure you use the tool to center it the best you can (before you tighten down the flex plate, feel the extents in each direction, and work to center it while you snug it down to hold the clutch disk)

Originally Posted by Previologist

Do you install the cut bolts first and use them as extra dowels, or screw them in once you have it close just to tweak the final alignment? I like the idea but might try it once without just to see if I get lucky.

I don't think I'm going to get lucky on the flywheel. I'm no expert but to me it looks like new flywheel time.

The belhousing dowels are very short. The extra bolts would be 2-3" longer and help align and hold the transmission while you are trying to slide the input shaft into the clutch - otherwise if you aren't careful you can move the clutch out of alignment or put excessive pressure on it. Some manufacturers actually use studs on a few of the engine/trans fasteners just for this reason (see: Subaru).



-Charlie

[Previologist]

any flywheel recommendations, or ones to avoid?

[davidch]

For installation "rails" I have used, to good effect, a pair of axles from a small motorcycle. Most any 50-175 Honda/Yamaha/Suzuki/Kawasaki has a 12mm front axle with 1.25 thread. These are plentiful on eBay.

The photo shows such an axle with the nut still installed.