Refitting Gearbox

[maytag]

Originally Posted by aussieboxy

Have replaced the clutch but having a hell of a time getting the gearbox back it.

Issues getting it to line up. Have used a clutch alignment tool so the clutch should be right.

Any tips?

First and foremost: make sure you have the correct clutch.
I learned the hard way that the 5-spd clutch is different from the 6-spd. Same spline count, different diameter. Barely. So the input shaft wouldn't go in.
Once I had the correct clutch in, it sunk with a resounding "thunk".

I had the trans on a floor jack, balanced, and aimed it with my hand.

Sent from my SM-G930T using Tapatalk

[aussieboxy]

Originally Posted by maytag

First and foremost: make sure you have the correct clutch.
I learned the hard way that the 5-spd clutch is different from the 6-spd. Same spline count, different diameter. Barely. So the input shaft wouldn't go in.
Once I had the correct clutch in, it sunk with a resounding "thunk".

I had the trans on a floor jack, balanced, and aimed it with my hand.

Sent from my SM-G930T using Tapatalk

Yep it's the right clutch. Placed it on the spline before fitting

[Gilles]

Buy two metric bolts to match two of the ones that attach the engine to the gearbox (one at each side) grind their hex heads, and cut a slot with the Dremel to facilitate their removal afterwards with a thin flat screwdriver, once you bolt these 'studs' to the engine you will be able to 'hang the gearbox on the studs' and the gearbox will slide right in position.. it is amazing how easier it will be!

I have used this tip at least 3-4 times within the last 10 years and always worked like a charm…

Thank you FCP..!

[aussieboxy]

Originally Posted by Gilles

Buy two metric bolts to match two of the ones that attach the engine to the gearbox (one at each side) grind their hex heads, and cut a slot with the Dremel to facilitate their removal afterwards with a thin flat screwdriver, once you bolt these 'studs' to the engine you will be able to 'hang the gearbox on the studs' and the gearbox will slide right in position.. it is amazing how easier it will be!

I have used this tip at least 3-4 times within the last 10 years and always worked like a charm…

Thank you FCP..!

Nice idea Thanks

[Gilles]

Sorry, but the credit belongs to JFP (typo)..

[aussieboxy]

Ok. This is not making sense to me. I have replaced probably 15 clutches in many different cars over the years so I should know what to expect.

The story to date.

Clutch was on it's way out & at 228,000 Kms (+140,000 miles). Have had car since 20,000Kms on the clock.

Removed gearbox, removed clutch, flywheel & RMS.

Replaced RMS, refitted flywheel which was in good condition, replaced clutch & pressure plate using clutch alignment tool. New clutch was identical to one removed & tested on gearbox spline before fitment.

Have attempted to refit the gearbox twice now, second time using a couple of guide bolts as suggested & it still won't slide in. Checked to ensure throw out bearing & arm were fitted correctly & not abstructing.

Have got a bolt om each side of the bell-housing slowly tightening but getting way too much resistance for my liking, I mean it's really hard to tighten.

Have checked the angle & the spacing from box to block is pretty close all the way round.

WTF is happening?

[aussieboxy]

Ok disregard. It's in