Cascade Crew

Xophertony · Posted: Sat Sep 02, 2006 6:45 pm Post subject: OMFG trannsmissions suck!

day went great, i got to my dads, had the tranny and clutch/flywheel out inside of two hours, took a while to get the flywheel resurfaced.. then putting it back in... we spent an hour and a half fighting it. then gave up for the day.

paul.......
you doing anything tomorow? i'll buy you lunch if you come and work your magic. please? Very Happy

we tried chris lifting it and me guiding, tried it the other way, tried it with jacks... etc..

oh, also, the pilot bushing won't come out. auto zones smallest puller is too big, and the grease pressure tool i bought at napa won't work. so we are re-using the original pilot bushing Rolling Eyes

(elegedly replaced @ 110K miles.

Dewey316 · Posted: Sat Sep 02, 2006 6:49 pm Post subject:

You guys did you the clutch alignment tool?

Mark and I had a hell of a time getting my tranny in when I did the clutch last. Sometimes brute force is what wins out, just keep moving it around, and pushing forward.

Or, put a hair around it, it will go. Very Happy

PS -- Paul went out of town this weekend for the holiday (I already tried to get him to help with my fuel pump. Wink

).

Xophertony · Posted: Sat Sep 02, 2006 7:02 pm Post subject:

dang....

and yeah we have a clutch alighnment tool. it came with my $94.32 clutch kit. we are going to try using TWO jacks tomorow, to get it at juuuusssst the right angle before the moment of insertion.

Dewey316 · Posted: Sat Sep 02, 2006 7:03 pm Post subject:

Remeber, turning the tail shaft helps, because it could be, that you just aren't getting the splines to catch.

Xophertony · Posted: Sat Sep 02, 2006 7:04 pm Post subject:

yeah... we had it in first so we could do that. but that is a good thing to keep in mind, i know i was not as on top of that as i could have been Embarassed

if only i had a trannsmission jack Rolling Eyes

Twilightoptics · Posted: Sun Sep 03, 2006 8:19 am Post subject:

Transmission Jack? Two jack stands?

Dude, you're talking more trouble there. You pretty much have to bench press it or have it on rollers. You can get it lined up at an angle, and try to slide it from the jack stand.

The trans probably did slide through the splines, you're having trouble getting it into the ...... used...... pilot bearing. This is when there is about 3/4ish" between the bellhousing and the trans flange.

All you do is have one of you down there wiggling the trans trying to get it to go, and have someone go press on the clutch. Slides right in.

Did you get the hole puller thing or the pilot bearing puller? Told ya the pilot bearing puller wouldn't work. The other puller comes with a slide hammer I remember now.

Another thing you could do is use a chisel and chip the thing out until it breaks. I've heard of this, but never tried it. Tools of the trade.

Used pilot bearing = worn input shaft bearings.

Xophertony · Posted: Sun Sep 03, 2006 9:34 am Post subject:

the one that comes with it's own slide hammer is $70 to buy, can't rent. the other "pilot puller" from vatozone needs trhe customers slide hammer (my dad has one) and it is too big for the pilot bushing. the 3rd thing i bough screws into the pilot bushing and has a grease fitting. it would not work either, my dads grese gun can not exert enough force, i think it requires an air powered grease gun.

i am going to try using the clutch alignment tool as my rod that is the same size as the pilot bushing. i'll pack the grease and hammer it out. it will work... it has too. if not i will use a chisle to destroy it.

iansane · Posted: Sun Sep 03, 2006 11:06 am Post subject:

There wasn't one that used the fingers to pull it out from the backside?

Twilightoptics · Posted: Sun Sep 03, 2006 4:25 pm Post subject:

Your autozone sucks.

Xophertony · Posted: Sun Sep 03, 2006 5:48 pm Post subject:

Twilightoptics · Posted: Sun Sep 03, 2006 7:01 pm Post subject:

heh heh heh heh

DO NOT under ANY CIRCUMSTANCE, bolt the trans/xmember in without it in the pilot bearing. You can bind the trans and cause lots of problems.

Quasi-Traction · Posted: Sun Sep 03, 2006 7:48 pm Post subject:

we put the crossmember in tightly enough to hold but there's a lot of play in it.

I swear I have NEVER had this much trouble putting a transmission in. EVER. I've never seen a manual transmission put up that much of a fight.

Tony's dad mentioned something I'd been thinking about a couple times when we got it super close (both using a jack and using the benchpress method) to getting it in. I kind of think the pilot bushing isn't in all the way or there's something in the hole of the crankshaft where it sits blocking it from going in, like maybe grease or gunk or something.

If its not that I it might just be were' not getting everything at the right angle both on the front and rear of the transmission to get it in.

I don't know but after having that transmission on your chest for an 2 hours yesterday making 5,801 attempts to get it and another Hour today making 2,868 attempts. I'm beat.

nap time. YAY.

rjmcgee · The Hammer Joined: 08 Jan 2004 Posts: 2328

Damn, I 've never had any trouble with mine. Just lift, stick, and then start rotating and wiggling until it goes in.

One thing that could really screw with you is if you put the clutch disc in backwards. Would be easy enough to do and would give the symptoms your talking about.

Al Hasse · Posted: Sun Sep 03, 2006 9:51 pm Post subject:

Xophertony · Posted: Sun Sep 03, 2006 11:31 pm Post subject:

iansane · Posted: Sun Sep 03, 2006 11:57 pm Post subject:

One crazy old guy that came into my work one day mentioned that he'd use long studs threaded into the bellhousing boltholes so that he could just slide the tranny straight riding on thoe studs, then just replace them with bolts one by one after the input shaft seated correctly.

Quasi-Traction · Posted: Mon Sep 04, 2006 12:01 am Post subject:

Xophertony · Posted: Mon Sep 04, 2006 12:25 am Post subject:

well, i took it all off and set it down carefully, then picked it back up and put it back on carefully, but i never actualy read it the second time... Rolling Eyes

this is why i should always double check everything. Sad

90droptoproc · Posted: Mon Sep 04, 2006 1:30 am Post subject:

we faught this same problem when I swapped the WC T5 into the 91Z, 4 hours trying to "wiggle" it in with all the above methods, no luck

pulled it back out, added more lube eveywhere on the input shaft, put it back up and it slid right in.
not sure if it was a fluke, but if you are there anyways Rock on!

Twilightoptics · Posted: Mon Sep 04, 2006 9:23 am Post subject:

good call ian. You guys did put grease on the splines on the trans and lots of grease in the pilot bushing?

It just needs to be flush with the crank recess.