I've been bench pressing my T5 for the last hour, but I can't seem to get it installed all the way into the bellhousing...It stops about 1" short.

I borrowed an "alignment" main shaft from a local shop to align the clutch. With a couple of smacks using the palm of my hand, the main shaft goes in snug, further than the T5. It takes a yankin' to pull it back out...I figure that's good, right? Tried this 3-4 times to make sure it is lined up right.

I then tried 3-4 times to get the trans in and it stops short each time...I try to push/force/jiggle it with all my might, but no go. It just hangs there, 1" from where it should be. The 4 trans-to-bellhousing bolts almost line up , but they are just a bit off.

Is this common? What the heck is wrong? This is a new trans with a new clutch and new roller pilot bearing. Lubed up with disk brake grease as instructed...the "alignment" main shaft went in, why won't the trans? I compared the 2 shafts and they are identical, except the T5 shaft is larger in diameter where it slides into the throw-out bearing...I even slid the throw-out bearing onto the T5 shaft and it fits fine.

HELP

 

The tranny should slip in without any problems, my guess is the clutch and pressure plate are not properly aligned. Realign the clutch with the manishaft (or alignment tool that came with the clutch) and keep it in there while tightening the bolts. The test shaft you have should then slide in and out easily (no hammer blows) and so should the tranny.

 

Most likely the pilot bushing is screwed. The alignment tool should slide in easy if the clutch isnt out of whack.

 

The plastic alignment tool slides in fairly easily...The shop suggested using the steel shaft because the plastic ones don't always line things up right (obviously).

I'm going to take the bellhousing off, loosen things a bit, then use the steel shaft to align it all and retighten...Thanks for the suggestion!

I can't see the pilot bushing being bad as it's brand new

 

once you have the clutch aligned with the tool if you still have a problem getting the tranny to but up against the bell housing try this. getthe tranny within an inch like you did before. install the slave cylinder and have some one GENTLY depress the clutch pedal about 1/2 way. the tranny will pop right in.

 

I would try that, only problem is, I don't have the clutch hydraulics installed yet

That was my next step...I'm swapping from auto to manual.

 

Did you check the alignment of your bellhousing? If your out of alignment with that, nothing is going to work correctly especially
a trans install.

 

I tend to think the clutch is not aligned properly. Loosen the pressure plate and realign using a steel shaft. The transmission should absolutely slip all the way in without a problem.

 

Your mainshaft isn't getting all the way in - most likely hitting the side of the pilot bearing other than going all the way in. Take it from me, make SURE everything is lined up 100%!!

I destroyed a pilot bearing, as well as my tranny's mainshaft (had to get it rewelded and then turned down.

 

Thanks Guys...I am going to attack it again today. I will be triple checking everything for alignment. Very glad I have the steel mainshaft to help make things right...wish I used it the first time. I really thought I had everything lined up right.

Stay tuned!

 

Me and a buddy fought with my t5 for several hours. Wiggle Wiggle Jiggle Jiggle - still like an inch to go. Eventually everything lined up and THUNK it slid completely in if you are sure everything is alligned just play with it till it goes in.

 

trick is to push the clutch pedal and itll pop right in. every single time ive done a clutch thats what ive had to do.

 

What type of T5 did you get? Is it a V8 or V6? The splines are different on the V6, but one thing few people know is that the V6 input shaft is about 1/4 to 1/2" longer than the V8. If you are trying to put a V6 behind a V8 you will need to very carefully trim about 1/4" off the end of the input pilot bearing surface, or the input shaft will bottom in the crankshaft and ruin the transmission. I know, I've done this conversion. I trimmed mine by taping up the journal and then using a cut off wheel in a die grinder. Cut real slow, and let it cool, or you will ruin the heat treat on the bearing surface. I've got 20,000 miles on my conversion, so far so good.

 

I've had the exact same problem with mine in the past. I found out that it was the throw-out bearing binding (cocking)on the smooth part of the input shaft as you try to slide it in.

Just "jiggle" the clutch fork as you slowly slide it in towards the block. I must've bench pressed mine like 6 times before I discovered that!! Boy was I sore!

 

IT IS IN!! The clutch must not have been lined up right...

I loosened the pressure plate bolts, slid the mainshaft in, torqued the bolts to 30 ft lbs., reinstalled the bellhousing and then bench pressed the T5 one last time...it slid in like a glove! Snugged up the 4 bolts and wiped my brow...

Now, to bolt-up the beautiful new Spohn crossmember and torque arm, then the clutch pedal & slave, then switch wiring...almost done!

I need a massage...damn I'm sore

 

Just went through this myself, complete with line-up issues as well. Finally undid everything, realligned and it went in. Incidentally, is there a recommended break-in for a new clutch? Was wanting to go to the track tomorrow night if it won't screw the new clutch up...anyone know?

 

Centerforce put a bright orange sheet of paper in my box that says go easy for 500 miles, then have fun...that seems like a long time to wait before going full throttle, but they must say that for a reason

 

i had the same problem with mine, you gotta press the clutch in, and be carefull you dont bend the disc, glad you got it in, centerforce d/f is awesome, i didnt go easy for 500 miles more like 300

 

Good Deal!! Let me know how ya like that G-Force!

 

How do you like your G-Force???

 

He loves it

At least that's what he told me