I have a buddy helping me with this install but my gearbox is being a bitch! We just can't get the bellhousing all the way on. I used a clutch alignment tool and was very careful to make sure the disc was centered. Its like something is blocking us from the last inch or so. We can get the studs aligned but cant get it all the way in. I have turned the flywheel a bit to try an align the splines. Any helpful tips greatly appreciated. I will be losing my help shortly so I will continue to search on the forum but so far everyone says " install is the reverse of removal" but this thing just doesn't want to go in. Thank you for any advice!!
 
I have a buddy helping me with this install but my gearbox is being a bitch! We just can't get the bellhousing all the way on. I used a clutch alignment tool and was very careful to make sure the disc was centered. Its like something is blocking us from the last inch or so. We can get the studs aligned but cant get it all the way in. I have turned the flywheel a bit to try an align the splines. Any helpful tips greatly appreciated. I will be losing my help shortly so I will continue to search on the forum but so far everyone says " install is the reverse of removal" but this thing just doesn't want to go in. Thank you for any advice!!

Check the input shaft on the gearbox isnt worn ie pull the box back & see if it has any side to side
up/down movement.
Is it the right clutch did you try it on the input shaft.
 
Can you get a couple of nuts on? if so lightly fit two and give the gearbox a damned good shake/wiggle, do not force the box on with the nuts as you might break something.

Edit just read you said an inch, that says to me the issue is with the spigot bearing/shaft

Friction plate the correct way?
 
I had similar a couple of years ago and, although I was aware, I still managed to slightly damage the splines in the plate and it wouldn't go in that last bit. You could also have damaged the bush in the crankshaft.
I remember the frustration well.
I was working in terrible conditions when I did mine, outside, raining and winter cold too.
 
Some bits of M10 studding can help guide the box true and level so I've read. I've only had my box out twice in 16yrs, first time it plopped straight in so I was expecting the same on the 2nd time, but I was cold and wet in poor light so I'm blaming that.:D
 
UPDATE: Thanks for the replies. My buddy that I asked to help me is Drago's twin (ala Rocky III) Seriously, 6' 8" , 265lbs of chiseled muscle. I figured he was the best candidate to manhandle that gearbox and transfer case. I must not have been too clear on the task explanation as he showed up looking like he was going to play a match at Wimbledon-fancy white shorts and shirt, with flip-flops. I had to find some sweat pants stretchy enough to fit his big ass and cut the legs off to make shorts out of them. The wifey got a good show as he stripped down to put them on. Anytime there is a party all the ladies are making googly eyes an whispering to each other-they can't help themselves. Anyway after a few hours of unsuccessful wrenching I posted the above begging for help. After that, his wife was blowing up his phone and he was keen to leave. I knew if he got out of here that would be the last I saw of him until I completed this job. We didn't get it to fit so I finally relieved him of duty and I figured he would text all of my other pals and alert them to screen me out as it is a very unpleasant task that I am asking help with. I managed to spill about a half gallon of gear oil under the Defender so we could waller around in it to make it extra pleasant. Mosquitos are in full bloom right now and it was 92F today so you can imagine the working conditions. I had the dreaded spline failure between the gearbox and receiver gear. Ashcroft was kind enough to ship me a rebuilt unit to Florida. I decide whilst that behemoth was out I would put in a new pressure plate, clutch disc and throw out bearing (terms we use over here in the states). Luckily for me I didn't get it installed while Drago was here because after he left and I was wondering around in the garage feeling dejected, I saw the throw out bearing in the new clutch kit box! HOLY **** BATMAN! In my haste to get help I had forgotten to install the new bearing. I lowered the gearbox and transfer case to the floor and installed the bearing. I decided since I was totally caked with 30 years of grease and gunk I would continue the task. Here is what I did and maybe this will help someone. I used an engine hoist put through the left door. I connected a chain to that stud where they gearbox and transfer case meet on the right top side. I attached a come-along to the front side of the gearbox just behind the bellhousing. (come-along over here is a hand operated ratchetting wench, maybe you have another term for them over there?) Both chain and wench connected to boom of hoist. I was able to use the wench to raise the front of the gearbox to match the angle of the engine which is pointing down due to the crossmember and transmission support brackets being removed. When we were "manhandling" the devil's gearbox, we could get it close but it just simply would not mate up. (Like a lot of my dates in high school.) I got it close by manipulating the engine hoist in position. Then I got under the vehicle and attached 3 large C clamps between the bellhousing and the flywheel cover. I snugged the clamps up until the space all around the bellhousing was about the same top to bottom and left to right. Now I tightened each one a little at a time until it was getting taught. Then I slipped a 13MM spanner (we call them wrenches by the way) in the space between the bellhousing and flywheel onto a pressure plate bolt and turned it ever so slightly to align the splines. I continued to tighten and move the flywheel and BADDA BING! that mofo slipped into place. Jubilantly I sent a Whatsapp to Drago and told him I was successful and that the muscle between your ears is more powerful than those on the arms. He then informed me he was planning on returning tomorrow to assist. My ass he was. Anyway, that's how I conquered this gearbox issue and I removed it and installed it all by myself so I hope this helps someone to just "Getter Done"!
 
UPDATE: Thanks for the replies. My buddy that I asked to help me is Drago's twin (ala Rocky III) Seriously, 6' 8" , 265lbs of chiseled muscle. I figured he was the best candidate to manhandle that gearbox and transfer case. I must not have been too clear on the task explanation as he showed up looking like he was going to play a match at Wimbledon-fancy white shorts and shirt, with flip-flops. I had to find some sweat pants stretchy enough to fit his big ass and cut the legs off to make shorts out of them. The wifey got a good show as he stripped down to put them on. Anytime there is a party all the ladies are making googly eyes an whispering to each other-they can't help themselves. Anyway after a few hours of unsuccessful wrenching I posted the above begging for help. After that, his wife was blowing up his phone and he was keen to leave. I knew if he got out of here that would be the last I saw of him until I completed this job. We didn't get it to fit so I finally relieved him of duty and I figured he would text all of my other pals and alert them to screen me out as it is a very unpleasant task that I am asking help with. I managed to spill about a half gallon of gear oil under the Defender so we could waller around in it to make it extra pleasant. Mosquitos are in full bloom right now and it was 92F today so you can imagine the working conditions. I had the dreaded spline failure between the gearbox and receiver gear. Ashcroft was kind enough to ship me a rebuilt unit to Florida. I decide whilst that behemoth was out I would put in a new pressure plate, clutch disc and throw out bearing (terms we use over here in the states). Luckily for me I didn't get it installed while Drago was here because after he left and I was wondering around in the garage feeling dejected, I saw the throw out bearing in the new clutch kit box! HOLY **** BATMAN! In my haste to get help I had forgotten to install the new bearing. I lowered the gearbox and transfer case to the floor and installed the bearing. I decided since I was totally caked with 30 years of grease and gunk I would continue the task. Here is what I did and maybe this will help someone. I used an engine hoist put through the left door. I connected a chain to that stud where they gearbox and transfer case meet on the right top side. I attached a come-along to the front side of the gearbox just behind the bellhousing. (come-along over here is a hand operated ratchetting wench, maybe you have another term for them over there?) Both chain and wench connected to boom of hoist. I was able to use the wench to raise the front of the gearbox to match the angle of the engine which is pointing down due to the crossmember and transmission support brackets being removed. When we were "manhandling" the devil's gearbox, we could get it close but it just simply would not mate up. (Like a lot of my dates in high school.) I got it close by manipulating the engine hoist in position. Then I got under the vehicle and attached 3 large C clamps between the bellhousing and the flywheel cover. I snugged the clamps up until the space all around the bellhousing was about the same top to bottom and left to right. Now I tightened each one a little at a time until it was getting taught. Then I slipped a 13MM spanner (we call them wrenches by the way) in the space between the bellhousing and flywheel onto a pressure plate bolt and turned it ever so slightly to align the splines. I continued to tighten and move the flywheel and BADDA BING! that mofo slipped into place. Jubilantly I sent a Whatsapp to Drago and told him I was successful and that the muscle between your ears is more powerful than those on the arms. He then informed me he was planning on returning tomorrow to assist. My ass he was. Anyway, that's how I conquered this gearbox issue and I removed it and installed it all by myself so I hope this helps someone to just "Getter Done"!

Sometimes it is easier to turn / wiggle the output shaft from the gearbox while pushing it home ...
 
Well done, getting a wiggle on helps a lot.
I was once changing a clutch on my turbo diesel by removing the engine [ for me the better way as I have a tractor/loader ] I had a mate come and help me by guiding motor back in, as I slowly lowered the motor into the engine bay my mate suddenly shouted stop stop. What wrong I asked ? Nothing he said, Its gone into place ! :D You never know have had others be as difficult as yours.
 
Some bits of M10 studding can help guide the box true and level so I've read. I've only had my box out twice in 16yrs, first time it plopped straight in so I was expecting the same on the 2nd time, but I was cold and wet in poor light so I'm blaming that.:D

I actually tried this on a truck the other, and to my bitter dissapointment it made sweet fanny adams difference, and I had such smug high hopes!
Something has changed on the clutches we are using, as getting the splins to engage is now an utter arsehole.

Fastest time I have ever done a heavy truck clutch (daf xf105) is 1hr15mins start to finish, now I can spend an hour wrestling the box back in.
 
Normally just put a socket on the crankshaft pully to turn the engine.
Glad you got it in.
 

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