Technical Replacing Clutch, can't get gearbox back on :(

[Guy1195]

Hi chaps!

First post here and first Fiat, always good to dive into the deep end haha!

I'm in the middle of doing the timing belt and clutch replacement, the clutch is now in and looks bob on in terms of being centered! Even used alignment tool. The gearbox just won't go back on though.. have tried using a jack and also just tying it up and using an engine hoist. It gets close but doesn't feel like the shaft wants to go into the Clutch...

Before I think about dropping the engine is there anything that I'm missing or any good tips? Sitting out in the snow trying to do it on my drive isn't nice!

Cheers!!

 

[Guy1195]

Also, if worse comes to worst, does anyone have any tips on dropping the engine? Only looks like it's held in by 1 mount at the moment, is there many wires/lines to unhook?

 

[Ralf S.]

Check the obvious.. Is the clutch centre the correct size for your output shaft? There are a few different engine options and the size of the output shaft or the number of splines might vary.

Take the clutch off the engine and see if it will go onto the gearbox shaft with everything off the car. If it doesn't, then that's the problem.

If it all looks okay, then there is no special technique I can describe. The gearbox shaft fits into the clutch, the gearbox slides in and then the last inch requires a bit of rotating/fiddling until the gearbox slots home.

Ralf S.

 

[Guy1195]

Absolute nightmare haha. The friction plate it's self fits the splines perfect, tried it before fitting as you say. It's just a nightmare working in the space I have. Looks like I'll just drop the engine then.

When fitting the gearbox it feels like the input shaft is miles away :/

 

[Ralf S.]

It's a bit drastic to drop the engine. When I changed the clutch on the Younger Mrs S's Titch, I managed to get the gearbox back on by myself. Stick the gearbox on a trolley jack so that it has some support... then you only have to lift it/manouevre it a few inches.... but best to break up a cardboard box and have that lying around on the ground, in case you drop the gearbox off the jack..

Ralf S.

 

[portland_bill]

The input shaft has to be directly in line with the crankshaft, any misalignment, in any direction, will make fitting difficult. It may also damage the centreplate. Don't force it in, if you bend the centreplate it will tear itself apart quite quickly. Patience, and tweaking slightly in 3 dimensions to perfectly align it, then it'll suddenly slide in.

 

[Guy1195]

I'm working outside and only have a **** poor £25 jack not a decent one.. It's a nightmare -_- I tried to use it anyway but because the gearbox was angled weirdly the stupid stud on the rear of the gearbox kept hitting other stuff haha.

Already stripped everything off the engine to take it out, however i snapped one of the injector connectors by accident -_- Going to remove the clutch again and try align it again.

 

[Guy1195]

IVE DONE IT!! Or at least the engine is out and gearbox back on hahah!! Now for the timing situation...