Mission: Transmission
 

Hey, back for more help with the car side of my electric car conversion. If you're not familiar with my conversion, I'm using a 1986 Mazda RX7, an ADC FB1-4001 motor (I think that's the right model number...it's been awhile) and Electro Auto's transmission adapter kit. All the clutch parts should be OEM for a non turbo, I think the flywheel is from Racing Beat. I'm FINALLY getting to put the motor in, after an exhausting battle to get clutch parts that fit. Now I'm having trouble when mating to the trans mission. Here's what's going on:

-The motor and parts all seem to mate easily. It only takes a short time to lower the motor into position, line it up, and bolt the adapter plate to the transmission. The slave cylinder and throwout bearing appear to function correctly from the outside, moving appropriately when the clutch pedal is depressed and released.

-Prior to mating, the motor spins fine when connected to a battery. Also, when in gear, the spline shaft of the transmission turns the correct way when pushed. In other words, as best as I can tell, both components of the issue seem to work separately.

-After mating, the car can be pushed forward or backward when in neutral. I cannot be pushed (with two people) when in any gear, even when depressing the clutch. With the back wheels off the ground, the motor will not spin with power applied, whether in gear or in neutral.

It looks like the problem is with installation, which is good because these are two things I'd rather not have to replace or service. Any ideas? Thanks in advance.
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Can you show some pictures of what you're doing? I think it may be something to do with the installation, but it's hard to say without seeing it. Does the bellhousing adapter have any adjustment to it? Is it possible it's on backwards or something?

I'd like to avoid picture taking. Right now it's in, but this is attempt 3, so it's hard to do it all over again before I hopefully get at least some theories to work with. The adapter plate is flat and has holes that match the bell housing bolt pattern, so it can't go on backwards.

I basically have the clutch assembly mounted to the motor, and I lower it in, match the splines, and use the bolts on the adapter plate to pull it all together.

It sounds like something is getting pinched or a bolt is contacting a part of the rotating assembly

Well, something is causing the input shaft of the transmission to be misaligned. Does the motor you're installing have any alignment studs? Because if the bolt holes are even the slightest bit larger than the bolts, you'll have enough slop to cock the input shaft when it all goes together.

http://www.negative-camber.org/crisp...nsionbolts.jpg

See, the hollow alignment pins are at the top right and bottom left.

Okay, took everything apart again and found the issue (I think):

The "critical distance" is wrong. Again, my adapter was designed for a TII and works for the most part, but I need to make an adjustment to the adapter.

I need help here. If anybody has a N/A, 86-88, I need to know the distance from the surface of the motor to the contact surface of the flywheel. If anybody can give me this number or show me where to find it, I will be most thankful.

That dimension is somewhat variable do to flywheel resurfacing. Don't be lazy. Take it apart, slide the clutch assembly onto the tranny and measure the shit yourself. Your either bottoming in the splines or don't have the proper relationship at the dowels.

Do you have machinists measuring tools?

No I do not have machinist measuring tools. I barely have normal tools to be honest. I'm not a grease monkey, mechanic, or even really a car enthusiast (other than electric cars).

I'm not trying to be lazy, but the way this is supposed to be done is to copy the motor to flywheel distance from the stock configuration in my conversion. But I bought my car with no motor so I didn't have the opportunity to do it myself.

I will try what you suggest, but I don't really see how I can do that. As soon as I start putting clutch parts onto the transmission, it would seem I would lose all way to measure the distance to the motor. I only posted the request because if someone happens to be working on a car similar to mine, they are in a better position to have the stock configuration available.

Obviously if nobody responds, I will be trying to find a way to measure it myself, but I posted here for help. Telling me I'm lazy does not help.