Hi,i'm having real prolems locating my newly built 2.5 into my car,i just can't get it to locate into the gearbox. It's almost there,but can't get the last inch to locate. I've tried everything with no luck.
Anyone have any advise to help me,it's drivivg me insane!

Thanks,Tim

 

When the clutch was fitted and bolted up was a clutch alignment tool used to ensure alignment with the spigot bearing in the end of the crank. Or have you fitted a new clutch and have inadvertantly got the wrong friction plate which will not fit the splines of the input shaft. Just two thoughts hope they help

 

The clutch plate HAS to be spot-on in alignment.
Go to MarkA's project thread in Projects, he has just gone through this misery (it's as bad with a 2 liter believe me.....) and has some solutions.

Graham.

 

its worth checking the, flywheel guard which is bolted to the bottom of the engine. wen i rebuilt my engine i had to lift the gear box up myself, which caused me to bend it up getting it traped between the engine and gear box.

also the studs on both sides of the engine will be very tight so u will need to pull the gearbox in by the bolts (u couldnt do it by hand)

also have u tied the engine back, so it dont lean to the front?

 

Id left the pitching damper on mine which wouldnt allow it to locate. When I took it off I could raise the box on a jack and it went on quite easily.

 

Thanks for the advise guys! im about to take it out again,re check the clutch and make sure nothings in the way.

Thanks,Tim

 

make sure you have the dowels in the right place, between the engine and box ,
Tim

 

Check all as above including engaging the clutch arm

It took me 8 goes at getting the two to mate up. In the end it was my friend who got bored with messing around and slowly tighted each bolt in turn in a clock-wise fashion. At one point I had to look away because the bell housing was flexing!!
But it suddenly slipped in, looking back the engine and gearbox dowells did not match up 100%, even after appying grease etc.

Mark A

 

I machined the 2 side dowels on mine by 0.2mm dia to ease things and a lot of coppaslip.
Engine out/gearbox out, both a real pain.

Graham

 

Hi,the problem is definately clutch alighnment issue. I have taken the clutch off and the engine slots in straight away!
One thing i did notice is the exeedy clutch plate is a really tight fit onto the spigot.Is this normal? as i think this is the problem,as i was sure it was set right.

Thanks,Tim

 

Tim,

This is just an idea that has just popped into my head..... are with me, it might be stupid...

What if, you were to leave the clutch cover bolts slightly 'not tight', and then slide the engine onto the box, and then tighten the bolts through the starter motor hole.... at least nip them up a little, then maybe remove it again and do them up fully, clearly it wouldn't need to come right out, just off far enough to get to the bolts...

Like i said, might be daft.... i can't honestly remember how much access there is through the starter hole....

 

Hi,

Just checking you have the release bearing clip (the cage bit that holds bearing to pressure plate) on the clutch itself and not on the bearing. If having trouble an old input shaft from a wrecked gearbox makes an excellent aligning tool

George

 

It's in!The clutch was ok,i think it must have been the tightness of the clucth.
One thing i have learnt is if you have to force then it's not right.When it did go it just slid in with hardly no effort.
Thanks for all the advise,you've been great as always!

Tim

 

That is so Impreza!
Not designed to be worked on.

Well done.
Graham.