5 Speed Install Problems - 5SFE, Won't Slide In Options

[Shytheed_Dumas]

So we managed to pull the old tranny out, installed a new release bearing, lubed the splines, installed the clutch with the alignment tool and torqued the pressure plate to spec. Using a 3 ton floor jack and an extra set of hands we have lifted the tranny into rough position with the rear motor mount set into the bracket, but unconnected. The lower cross member is hanging in front with the nuts just started on the rear. The mount near the battery is off for now.

Sounds like we should be good to go, right? No.

First issue is that the rear mount causes the tranny to twist a little. We can get it lined up to near perfect with a pry bar, but I don't like any binding if I can help it. Once aligned we have no problem getting the shaft to touch up with the clutch - in fact I know we have engaged the splines more or less, because turning the flywheel causes everything in the transmission to turn.

But it stops dead at this point, and the closest we have come to pusing it home is with about 1-1.5" to go all the way around the bell housing - defintely before hitting the guide pins, so that's not the hangup. When it stops going in, the transmission seems to pivot as though it is balancing on the shaft. We have quadruple checked, and there is nothing jammed between the housing and motor.

So what could I be getting stuck on?! My only guess is that I didn't do as good a job as I thought with the alignment tool? I'm out of town on business and planning to pull the plate/clutch and try again this weekend or early next week, but if there are ANY other ideas or suggestions, I'm all ears.

This post has been edited by Shytheed_Dumas: Nov 28, 2007 - 7:54 AM

[Shytheed_Dumas]

JOB IS DONE!!!!

Finally figured out that it was just a matter of technique, and that the shaft was getting hung up on the disc. After playing with the old transmission and clutch plate we figured out how the transmission had to move to take the splines and six attempts later it slid right in. Leaving the rear motor mount off was definitely the right thing to do. So THANK YOU for the tips! I still have to fill the tranny with fluid and tie up a couple of loose ends like battery, air filter, etc., and then I'm ready to give it a go. Fingers are crossed!

Any solid recommendations on brand of gear oil? Also, what is the recommended weight? I forgot my books at home and want to pick everything up on the way home. Never mind - 75W-90 and RP seems to be preferred here. 3.75 quarts is refill capacity on the 5 speed, right?

This post has been edited by Shytheed_Dumas: Dec 7, 2007 - 9:53 AM

[njccmd2002]

JOB IS DONE!!!!

Finally figured out that it was just a matter of technique, and that the shaft was getting hung up on the disc. After playing with the old transmission and clutch plate we figured out how the transmission had to move to take the splines and six attempts later it slid right in. Leaving the rear motor mount off was definitely the right thing to do. So THANK YOU for the tips! I still have to fill the tranny with fluid and tie up a couple of loose ends like battery, air filter, etc., and then I'm ready to give it a go. Fingers are crossed!

Any solid recommendations on brand of gear oil? Also, what is the recommended weight? I forgot my books at home and want to pick everything up on the way home. Never mind - 75W-90 and RP seems to be preferred here. 3.75 quarts is refill capacity on the 5 speed, right?

Some people use syncromesh here from penzzoil, difficult to get, have to order it. i think its 2.7 qts. Usually while you are filling, do it until it tops out and starts leaking.... GL

It took me a week to do this job too!