install transmission
 

hey y'all,

1992 300d manual transmission swap.

I've been working on it in spurts for the past few weeks. finally got all the parts and everything and now working on getting everything back together again.

Got the pedals mounted, Clutch cylinder pressure line ran, manual shifter mounted, got a new rear crank seal in there, got the flywheel mounted.

Aligned the clutch best i could using the tape wrapped around a screwdriver method. Checked it by eye that it looked pretty lined up.

Went to stab the trans in and i cannot get it to fully seat. fairly even gap all around about a 1/2 inch.

Can anybody think of anything i might be missing??

How exact does the clutch need to be aligned?

Do i need to do anything with the clutch fork/ throwout bearing?

Thanks for any tips

https://youtu.be/6E9ATm7NmDU?si=-bv2-gWohAYRirZh

thinking i need to do this

Was it confirmed that the pilot bearing goes over the input shaft? With only 1/2" space I'm thinking either the pilot bushing/input shaft fit is off OR more likely it is an alignment problem. In a perfect world the best alignment tool is an old input shaft by itself but who has one of those laying around?

Try polishing and lightly oiling the forward tip (1/2") of the input shaft and lightly chamfering it with a file. Grease the splines on the input shaft very, very lightly. Too much grease will be thrown onto the disc friction surface. Attempt an install.

If this doesn't work and if separating is possible on this transmission, separate the bell housing and the transmission, confirm that the input shaft will go into pilot bushing/bearing. Loosen the clutch plate bolts enough to almost free the disc, install the transmission without the bell housing and jostle the transmission around evenly to center it up and before removing the transmission tighten the pressure plate bolts in an alternating and even pattern. Remove the transmission and reinstall to confirm success. Reattach the bell housing and install.

Is the disc absolutely in with the front facing forward? No chance it is backward?

The above is a lot of work, if time isn't critical it would be worth locating a centering tool. They work well.

I was going to suggest this.

Lemme know if ya need a hand.

I sent ya a text