Need advice for putting the tranny back in

[steel]

Hey guys. I finally got a chance to continue putting my jeep back together. It's a 79 CJ7 with AMC 258 i6 / 4.2l and T-150 Transmission . I started off swapping out the Transfer Case with a salvaged one I found. While I was it it I decided to do the clutch and pilot bushing. I'm having a hell of a time getting the transmission back in. I get it up and within half of an inch or less from getting the bolts started, but can't get it any closer. I know the clutch, flywheel and pressure plate are lined up, but can't get that last little bit. I tried getting it close, then turning the transmission output hoping it just needed the splines to line up. Anybody have any hints to get them together. Thanks

 

[Torxhead]

You could have used a lousy clutch alignment tool or the wrong pilot bushing. If you get it in close, like you stated, have someone push the clutch pedal in to free up the clutch disk and hope it works.

 

[Saddle Tramp]

What Torkhead said but I have to ask about the pilot bushing. Did you change it or pack it with grease? If packed with grease when the tip of the shaft is pushed into the bushing hole it can force the bushing out of the crankshaft and not let the transmission seat.

 

[Neuner]

Ditto on the pilot bushing. Did you test fit it on the input shaft tip before install?

Had similar problem. Bought longer bolts just to gradually pull it in close enough to use the actual bolts. Grease in the pilot bushing pockets forms an air bubble that resists the pilot tip going in. Will hear a small pop of grease when the air is pushed out.

 

[Posi]

If all else is good try using a couple long threaded rods as guides. Install two threaded rods in the 2 bottom holes, then add nuts, evenly tighten down. Works for me.

 

[IOPort51]

If all else is good try using a couple long threaded rods as guides. Install two threaded rods in the 2 bottom holes, then add nuts, evenly tighten down. Works for me.

this will help a lot.

one silly question, when you turn the output shaft to line up the splines, is the Transmission in gear?

 

[Hedgehog]

Are you hanging up on the indexing pins?

Don't use the Transmission bolts to draw the bell housing up. The tabs aren't strong enough for that sort of thing. Saying that sort of sounds like I'm saying not to use Posi's suggestion. Not really, he is using the threaded rod to tighten or draw the transmission. It is similar, but the loads would be different.

 

[steel]

Have a new problem now,checked the alignment again, it was off a little. But while I was putting the pressure plate back on, the bolt hole on the flywheel stripped out. now I'm looking for a new flywheel before I can go any farther.

As for the original problem, I did originally pack they pilot bushing with grease to get the old one out, but cleaned it out pretty well. I'll try the longer bolt thing when I get a chance to start finally putting it back together... Again.

Thanks for the help.

 

[Torxhead]

Make sure you have to correct size pilot bushing. Too bad about the flywheel, those threaded holes can get screwed up and ruin your day.

 

[Hedgehog]

If you have difficulty finding a fly wheel you might be able to weld the holes and re-tap the threads. I admit to not knowing if a flywheel is cast iron or steel.

 

[IOPort51]

I have broken a few bolts but never stripped the hole. The long bolts are just to line things up and hold things in the right plane without having to physically hold the Transmission up. A bolt with the head cut off about 2 inches longer than the original.

 

[Lumpy Grits]

Have a new problem now,checked the alignment again, it was off a little. But while I was putting the pressure plate back on, the bolt hole on the flywheel stripped out. now I'm looking for a new flywheel before I can go any farther.

As for the original problem, I did originally pack they pilot bushing with grease to get the old one out, but cleaned it out pretty well. I'll try the longer bolt thing when I get a chance to start finally putting it back together... Again.

Thanks for the help.

Easy fix with a Heli-coil insert.
helicoil,helicoil insert,helicoil inserts,helicoil kit, helicoil tap, heli-coil, helicoil tools

NEVER-EVER use grease on a pilot bushing! OIL only!!
LG

 

[Posi]

NEVER-EVER use grease on a pilot bushing! OIL only!!
LG

He used the grease to remove the old bushing, not on the installation of the new one.

I did originally pack they pilot bushing with grease to get the old one out, but cleaned it out pretty well.

Some folks use grease to remove the pilot bushing (messy), some use wet toilet paper (less messy, but still messy). A good choice is a bolt, a better choice is a tap. It's a good idea to soak the bearing overnight in oil.

Out in less the 30 sec

 

[Bent]

Have a new problem now,checked the alignment again, it was off a little. But while I was putting the pressure plate back on, the bolt hole on the flywheel stripped out. now I'm looking for a new flywheel before I can go any farther.

As for the original problem, I did originally pack they pilot bushing with grease to get the old one out, but cleaned it out pretty well. I'll try the longer bolt thing when I get a chance to start finally putting it back together... Again.

Thanks for the help.

I've got a couple helicoils in mine where I thought the threads where a little sloppy. It's been working well for a long time.

 

[Lumpy Grits]

Done the grease pack for removal of a bushing many times.
Have also used bread pieces--
Grease will also work(sometimes)on removing seals too.
LG

 

[Neuner]

I have an extra flywheel. Too bad you are all the way up North.

 

[Hedgehog]

I like the tap idea. never heard it before.

I know it works, but I will NEVER use the hydraulic method (grease, TP, any of it) ever again. For me it was MESSY and didn't work at all, not even a little bit. There's still grease splattered all over the frame and underside of the body.

 

[Lumpy Grits]

I like the tap idea. never heard it before.

I know it works, but I will NEVER use the hydraulic method (grease, TP, any of it) ever again. For me it was MESSY and didn't work at all, not even a little bit. There's still grease splattered all over the frame and underside of the body.

Like to have seen that happen-
BTDT when I used to small a dowel to 'pump' the grease.
LG

 

[steel]

New question. I removed the flywheel bolts and found this on one of the flywheel bolts. Is the remnants of a helicoil or something else? Summer is coming and really want to get this thing out of my garage and ready.

 

[Hedgehog]

Looks like Liquid Steel to me.