Mating Transaxle to Engine...advice needed

[specboxCO]

Copper grease on the splines makes a world of difference in my experience. First time I changed a transmission, it took me 2 days of trying to align it to get it to slide in. I've since done 10+ transmission changes and every time greased the splines and found it slips right in.

[Gelbster]

Careful with the amount of grease ! You need the highest "dropping point" temp you can find.

[Wanderer]

Had the same problem and ended up damaging the splines on the new clutch disc. Filed down the ends on the disc and used wheel studs to slide the trans on. Went right on.

[Gelbster]

For clarity:
You chamfered (with a file) the transmission side of the leading edges of the broached spline hole in the friction plate ?
If that is correct, it seems a good idea. How could it do harm ?

[JFP in PA]

Originally Posted by Gelbster

For clarity:
You chamfered (with a file) the transmission side of the leading edges of the broached spline hole in the friction plate ?
If that is correct, it seems a good idea. How could it do harm ?

The clutch disc already has a chamfer on the internal splines, he probably buggered it a bit and had to repair it.

[Gelbster]

Originally Posted by JFP in PA

The clutch disc already has a chamfer on the internal splines, he probably buggered it a bit and had to repair it.

Agreed, each spline of the friction plate is chamfered - but only in one plane(roughly like a chisel).
I think he filed a chamfer on the other two planes ?? So the leading edge of each spine is shaped like the point of a nail . That would be chamfered on all 3 planes.
This would require a thin file , lots of patience and a steady hand.
If all he did was repair damaged splines - good idea. But if he modified the profile of the leading edge of the friction plate splines, that is more 'interesting'.

[JFP in PA]

Originally Posted by Gelbster

Agreed, each spline of the friction plate is chamfered - but only in one plane(roughly like a chisel).
I think he filed a chamfer on the other two planes ?? So the leading edge of each spine is shaped like the point of a nail . That would be chamfered on all 3 planes.
This would require a thin file , lots of patience and a steady hand.
If all he did was repair damaged splines - good idea. But if he modified the profile of the leading edge of the friction plate splines, that is more 'interesting'.

Chamfering the splines on three sides would also weaken them. In reality, both the input shaft on the gear box and the disc splines are very mildly chamfered in a single plane, and if lubricated with the correct grease and properly aligned, will quickly and quite easily slide together. By far, the biggest issues we see when people have trouble getting the gear box back in is improper alignment and excessive force, which ends up in aggravation and damaged components. These things slide together easily with a reassuring "thunk" when it is done properly.