Is there some trick that I'm clearly missing? I've put the bearing into the e-shaft and the seal and every time when trying to get the input shaft of the transimission to go in we wind up destroying the seal in the process.

Unfortunately I'm doing this in my garage on jack stands which sucks but everything appears to be lined up as far as the input shaft into the clutch and what not however the input shaft goes into the clutch disc a decent amount and just stops every time with about 3/4 - 1" gap between the bell housing and the motor. I have the pilot bearing maybe 1/8 - 1/4 inch past flush on the e-shaft and the seal seats itself in a decent fashion but once I start trying to put the tranny in it just refuses to go all the way.

Anyone have any suggestions?

 

Maybe you have the seal in backwards. I know the first time install one I but it in backwords and it riped as soon as the input shaft touched it.

 

Slide the seal a little ways on the input shaft perhaps?

 

Jsplit,

Use a little vasoline on the seal so it doesn't bind on the tranny shaft. Then get the tranny mounted. You might have about 1/2" gap or so from the tranny to the bell housing. Use a longer bolt in a shorter hole to pull the tranny towards the motor. That will allow you to get the rights bolts going in the right holes.

 

Thats what I was thinking :\ dunno how well that will work tho

 

Tried that on the 2nd and 3rd seal I destroyed :\
I can never get the gap under maybe 3/4 of an inch. I've ran in the 3 bottom bolts a bit but it always leaves a massive gap up top.

 

try jacking up the front of the engine to tilt it back. Without the weight of the transmission, the engine would tilt forward. After I did that they match perfectly within a few tries.

 

Here is what I would do. Put the seal on the end of the alignment tool (one provided with clutch kit). Use a hammer and softly tap in. I did this with the motor on a stand and it was a snap to do. Good luck.

 

It's all in the angle, it sounds like. While I have never done an FD (mine being automatic) I can definitely see how much of a bitch it could be to get the engine at JUST the right angle to avoid the exact problem you are having. I've done dozens of cars in the past and with the exception of my little Mazda pickup and one Audi, I have always pulled the tranny with the engine, just to make the bolt-up easier.

Good luck, man....there are some knowledgeable people with good advice here. It just sucks that you are going thru the seals, those alone are not easy to get in and out sometimes!

 

Everything has to be lined up straight to go in properly. If there is more of a gap on the bottom, or top, then you are not lining it up straight. If you keep going in at an angle, you will continue to destroy your seals.


Earlier, someone suggested jacking the front of the engine up a little bit. If you can do it, that should help.

Good luck

 

assuming everything is still stock; take out the intercooler and the pipings; take out the battery and the tray. next, use the scissor jack that came with the car, and a small piece of wood and jack the engine up against the pulleys (use wood, so you won't damage them).

Thats the way I did it, but maybe you can use a engine lift.

 

Yeah I did jack up the engine on the last attempt and got everything with the bell housing / motor at least having the same gap all the way around.

I think part of the problem might be the depth of the pilot bearing and seal itself. I noticed on H-19 of the manual that it says .453-.482" of insertion depth for the bearing and I don't believe I have it that far into the e-shaft thus this would mean the seal wasnt as far in as it should be as well.

I've dropped the tranny for clutch work a handful of times and never had this much trouble but I never took out the pilot bearing and seal.

Luckily the bearing and seals are cheap cuz I'm going through these like nobodys business. Now I just have to wait till Tuesday for my latest shipment to arrive.

 

I don't think that the depth of the seal/bearing is real issue. As long as the seal goes in a little past the lip, it should be good enough.

 

I had the transmission out this weekend. The first time I pulled it years ago I had a real struggle getting the input shaft though the pilot bearing as well. This time I blocked the front of the motor up slightly and spent a few extra minutes eyeballing the clutch and pilot to make sure they were perfectly concentric. Even with an alignment tool I found the disc could be off just slightly. Slipped the tranny on and through the clutch disc. Jiggled the transmission slightly as I pushed and it slipped right in completely against the engine. I couldn't believe how easy it went compared to last time.

 

^ Damon....you're KILLING the poor guy! lol......

 

Yeah seriously :\

Well I will try another stab at it Wednesday evening assuming my new parts arrive.