I've finally got everything back together for my clutch change I have an 87 with the 2.8 5 speed. I'm having trouble getting it to mate up with the bell housing and I'm lost at what to do next I've had someone push the clutch pedal and its about a half inch away. I feel like its started in the pilot bushing but not fully. I've had to jack up the engine slightly to get it flush with the transmission and I've got bolts started. I'm not about to use the bolts to pull the transmission on. I've tried rocking it up and down no use any tips or helpful hints or am I missing something ?

 

Sounds like the disc wasn't lined up with a alignment tool.

 

Put the trans up in there and wiggle it around, and tighten the bolts FINGER TIGHT ONLY, NO TOOLS except maybe a socket to make it easier for your fingers to grip than trying to turn the bolt head itself, as you wiggle it around from underneath. It will gradually go in a little bit at a time. Once you get it in as far as it will go FINGER TIGHT ONLY, finish assembling the clutch hydraulics COMPLETELY, and have your assistant push the clutch to the floor. It will then be able to wiggle right in flush against the BH in one smooth move.

Whatever you do, DO NOT attempt to use the bolts to "draw" the trans up to the BH!!!!! You will SURELY destroy stuff that way.

 

I used the alignment tool. I'm hoping its not the pilot bushing I installed. I used a socket the same diameter at the bushing but with it being brass I hope I didn't damage it on install. I had someone push the clutch in and I've tried to get it pushed in more. It would rock before when it was about an inch away then I had a friend push in the pedal and it slid in to about a half inch away and now it feel more sturdy like its partially in the pilot bearing. Should I keep trying to wiggle it in or should I just drop the tranission back down away from the bell housing and inspect the pilot bushing. ? I don't want to have to take it to the shop because I have everything I need to finish after I get the trans in and bolted up.

 

Keep wiggling it gently, if that is working. You won't hurt anything that way. Keep finger-tightening the bolts, one at a time, as it goes in a little bit at a time. Don't use a tool on them until the trans is in contact w the BH.

 

Alright I'll try that once it gets a little warmer out. I remember the bolts being a pita to get out before and I had to ubthread them all the way with a tool but if I do end up having to drop the trans to inspection the pilot bushing do you thing I should just take the BH off and losen the pressure plate and get a metal alignment tool instead of the cheap plastic one it comes with to realign the disk? That's only if the pilot bushing is damaged and I have to get a new one. Sorry for all the questions its my first time doing a clutch change but I did my research before attempting it.

 

The plastic one should be OK.

If you have to pull the trans back out, first try leaving the BH on, put the tool in, and have your assistant push the clutch. That'll take all the force off of the disc and allow it to move freely in there. Using the tool, center the disc so that the tool slides in and out as freely as possible, then put the trans back in.

You should be able to see the bushing and tell if it's damaged.

How did you put it in? The correct way is with a piece of pipe or a socket or something, that only contacts it around the outer edge, nowhere near the hole; if you used something flat instead, you might have mushroomed its surface into the hole.

 

I used a socket the same size to tap it in but I'm afraid I put too much force on the bearing when taping it in. Thanks for the tip on freeing up the clutch disk without removing the BH that was one of my concerns I'm going to try a metal alignment tool because I feel the plastic one could have been off and I wouldn't have even known. I have a picture I'm going to try to upload of the flywheel installed and the pilot bushing. I have time off Monday and tuesday with the weather in my favor I'm going to try another attempt. To all who responded I appreciate the advice I'm hoping to have this thing up and running by this next week.

Here's a link to the image of my pilot bushing installed and the flywheel. http://tinypic.com/view.php?pic=fmlz6x&s=8#.VLoNh4co4wg

 

My favorite alignment tool is actually an old transmission clutch gear; only problem is, it's so destroyed, it cuts my hand when I use it if I'm not careful.

But the plastic ones have always worked fine for me when I've used em, as long as they slide in and out freely. (disc absolutely centered on the pilot, not with its weight hanging from the tool)

 

I wasn't sure if you could see the picture i posted up. I took more as I just tried again to wiggle the transmission in with some help and someone pushing on the clutch. I slightly have to jack up the engine to get everything centered but my jack doesn't hold well and decompresses after about 3 minutes. I took some more pictures of how close it is I feel like it should go in by now. Is there anyway I could send the pictures ?

 

In addition to what has been said above, I always leave it in gear and use a driveshaft yoke to turn the trans gears to help line the splines up also.

 

One way I use to line up clutch splines with trans is when installing disc have one if the female splines on top position then turn trans so the male spline is facing up as well . Makes it easier . Your pic if the bushing looks like you have been getting rammy . Just sit back have a beer , smoke or something on a break and go back at it. Gives your mind a break or u will end up hurting something getting mad trying to install it . Did u test your pilot bushing on front of trans before installing it in crank? That's another thing. Some have a sharp side and if facing out it will be fun sliding trans in good luck

 

I had the same issue with a 94 chevy truck i was putting a motor in a couple of weeks ago, Not sure how the clutch setup is made in these cars, mine is an auto, but the pickup had an external slave and clutch fork. My clutch fork was not centered on the pivot and was holding the pressure plate in the disengaged position. I kept wiggling until i made it butt up and bolted it together, but afterwards, the clutch would not engage. Could put it in gear without pressing the clutch at all. If its that close, you should be in the pilot bushing. I'd be looking for a wire between the engine and trans or something else keeping you from going together. Once its that close, it should just slide in if everything is right. Are your dowel pins hitting the right spot?