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disco 1 harrogate

Member
Hi peeps , just changed my clutch fork ( which means splitting bell housing ) however they won't go back together . I've pulled, pushed , shook , kicked,wiggled, hit , sworn and sworn some more . After 3 hours given up ! Any help what I have done/doing wrong would be a massive help . Any tips to get them back together ??
Cheers
 
put t/box in diff lock ,g/box in 1st or 2nd and turn out put flange at same time as you push ,ensure it is square all round bell housing
 
if you didnt brace the engine at the front and it sprung back level when you took the box off , you Might have moved the clutch plate upwards as the shaft came out of it on removal .
You might have to slot an alignment tool in to see if its shifted .

If its this,the box usually is about 1.5 inches from fitting and just wont go . tired arms and bleeding knuckles and a dose of pins n needles .

Hopefully its just a twist of the shaft as mentioned earlier :)
 
oooo just a thought ,did you put the fork and bearing together properly ? and the clutch rod isnt fowling as it can get in the way
 
stick a jack under the gearbox and make it level.. then turn the crank when mating it.

i usually find it's due to the gearbox angle being wrong and it binds
 
Use some M10 studding as guides in bottom two threads and slide in,turning shaft as James says-don't be brutal with it
 
Put it in gear and wiggle the rear flange as it goes forward, to align the splines ... look at the gap around the bell housing, it should be the same all round as it goes forwards, if not it is tipping and will bind ... :eek:
 
Thanks again , another quickie , if everything is level and square should it slide in quite easy or do you need to give it some ? I've got it as far as all the bolt holes are level and bell housing square ( this has taken about 5 hours of huffing and puffing ) therefore don't want to take it back 5 hours to check clutch alinement if I don't really have to . I'm about just over an inch away from bell housing becoming one .
Ps:free to good home wife who says " how much !!! ...You can do it yourself "
 
disco 1 harrogate said:
Thanks again , another quickie , if everything is level and square should it slide in quite easy or do you need to give it some ? I've got it as far as all the bolt holes are level and bell housing square ( this has taken about 5 hours of huffing and puffing ) therefore don't want to take it back 5 hours to check clutch alinement if I don't really have to . I'm about just over an inch away from bell housing becoming one .
Ps:free to good home wife who says " how much !!! ...You can do it yourself "
Click to expand...

pretty easy..once aligned, it just slides in. did you use an alignment tool or your eye?
 
disco 1 harrogate said:
Thanks again , another quickie , if everything is level and square should it slide in quite easy or do you need to give it some ? I've got it as far as all the bolt holes are level and bell housing square ( this has taken about 5 hours of huffing and puffing ) therefore don't want to take it back 5 hours to check clutch alinement if I don't really have to . I'm about just over an inch away from bell housing becoming one .
Ps:free to good home wife who says " how much !!! ...You can do it yourself "
Click to expand...

As Trax says, should just slide in like ... well anyways :eek: ...

I did one once on a sloping drive, that was a pig cos the weight was shifted and gravity didn't help ...

Any one local to give a hand, as you sound creamed ? 5 hrs is a long time with a heavy old box ...

Did make an alignment tool once from and old input shaft or you can whittle a broom handle down ...
 
Took me ages to get box and engine mated again but with a bit of threaded bar I managed to get a few studs through the gearbox holes and tightened nuts up to pull it together, it didn't mate exactly perfect, the tightening of the nuts pulled it together, and I had the shaft lined up.

Let us know if you've sorted it :)
 
Thanks again everyone , it's one of those " wish I hadn't started jobs " however it will NOT BEAT ME . Will keep you up to date . Going to drop gear box AGAIN this afternoon to check allinement , ( after a 10 hour shift at work ) then fingers crossed it will " pop " in .......god I hope it does.....
 
disco 1 harrogate said:
Thanks again everyone , it's one of those " wish I hadn't started jobs " however it will NOT BEAT ME . Will keep you up to date . Going to drop gear box AGAIN this afternoon to check allinement , ( after a 10 hour shift at work ) then fingers crossed it will " pop " in .......god I hope it does.....
Click to expand...

just dont wind it back together with bolts, FEEL it in whilst turning transmission to align splines
 
Huzzah.....after another 3 hours of pulling, pushing , wiggling and jiggling it finally popped in using everyone's tips and tricks , ended up rising the of the engine with a two ton trolley jack and a piece of wood ......pumped it up one pump at a time, then wiggled and jiggled after about five or six pumps in it popped .
MASSIVE MASSIVE THANK YOU
 
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