Having trouble mating trans with engine

[matta]

I have a 1998 4G63 motor going in my 96 gsx. the trans is a 96 awd 5 speed. I also have the 91-96 transfer case which is most likely irrelevant to this problem.

Im not sure if the output shaft is going ALL the way in? but, the transmission bolt holes are not all the way flush to the holes on the engine block. I've tried turning the crank pulley a little bit to line up and maybe the splines are not going together correctly. Was talking with one of my buddies and he says I need to get a clutch alignment tool, because I had to change out the flywheel on this motor I just got.

Give me some things to try if you may know anything. Im at a loss. It seems like the trans shaft is going in the engine, but not all the way to where the outer trans bellhousing is sitting flush with the engine

 

[Ghost_92TSi]

Did you use a clutch alighment tool when you put the clutch in, it holds the clutch centered while you tighten the pressure plate on it. If it is not centered it could very well be your problem.

 

[dsmspick]

Also make sure you have the correct flywheel. I had a fwd flywheel (told it was awd) and having the wrong flywheel cause the transmission to not go on at all. First I would check alignment with a clutch alignment tool

 

[miliman13]

Also make sure you have the correct flywheel. I had a fwd flywheel (told it was awd) and having the wrong flywheel cause the transmission to not go on at all. First I would check alignment with a clutch alignment tool

exact problem i had. they look so much alike.
but from what your saying it sounds like in correct Flywheel

 

[matta]

I have the correct awd flywheel, I already went through that problem a week ago , the transmission bellhousing is sitting about 1/2 inch from meeting with the engine block. maybe its the clutch alignment like everybody is saying

 

[jayson427]

Last time me and my buddy worked on a gsx we came across this. It was so hard to stab the output shaft all the way through we were worried to cause damage. But my buddy which is a big dude just man handled it with some force and it popped all the way in. So getting it to align properly is difficult sometimes. Try jacking the motor up and down for it to slip in. Good luck man

 

[matta]

Yeah it seems like the output shaft is going in maybe halfway. the dowel pins (dont know the technical name, sorry) that are on both bottom sides of the engine block...are lined up with the bellhousing holes too . I just dont want to break anything!

 

[MALaCasse]

put your pressure plate and clutch disc on the flywheel but only tighten the pressure plate down enough to keep the clutch disc from sliding down from its own weight. so the pressure plate won't be very tight. that will allow the clutch disc and trans shaft to line up easier when you install it. after you get the tranny and engine to mate properly pull the tranny back out and torque the pressure plate down. hope that's want confusing.

 

[bryanwheat]

put your pressure plate and clutch disc on the flywheel but only tighten the pressure plate down enough to keep the clutch disc from sliding down from its own weight. so the pressure plate won't be very tight. that will allow the clutch disc and trans shaft to line up easier when you install it. after you get the tranny and engine to mate properly pull the tranny back out and torque the pressure plate down. hope that's want confusing.

Or just buy an alignment tool. You can even make one with a deep socket and a roll of electrical tape. Find a socket that fits tight into the flywheel hole, than evenly wrap tape around d the other end to where it just fits thru the center of the clutch. It sounds kind of crazy, but it works well in a pinch.

 

[MALaCasse]

Or just buy an alignment tool. You can even make one with a deep socket and a roll of electrical tape. Find a socket that fits tight into the flywheel hole, than evenly wrap tape around d the other end to where it just fits thru the center of the clutch. It sounds kind of crazy, but it works well in a pinch.

An alignment tool would be nice but honestly, who wants to wait around to get one? . I prefer the method I posted (it does require more work) just for the fact that it is a true alignment of tranny shaft, clutch disc and throw out bearing. The socket and tape does work good too.

 

[Ghost_92TSi]

They have them at autoparts stores, the one I use and its fine.