HZJ 75 4.2 Installing new Clutchplate and pressure group, gearbox won't fit anymore

[Zijad]

Hi Guys,

Some weeks ago I found my clutch of my HZJ75 4.2 of 1995 was slipping, so I ordered a new clutchplate and pressure group and meanwhile demounted the gearbox.
Then I found that the clutchplate was still good, but rather greasy. So I looked further and removed the fly wheel and then found that the oil sealing of the krank shaft was not that good anymore. So oil came into the clutch house and that made the clutch plate to slip.
After fitting the new oil sealing, flywheel and a new top bearing, I started to install the new clutch plate and new pressure group. Since I did not have a pilot bearing tool to position the clutchplate exact, I used a similar sized(diameter) socket and then screwed the pressure plate into place. I then started to place the gearbox back in place, but then the problem came in. The final 3 cm between the clutch house and the engine couldn't get closer.... We tried lot's of stuff but it just didn't move the final 3 cm. We looked around the gearbox and we are very sure that it wasn't somehow blocked.

So now we have the question, how exact does is come when placing the new clutch plate and pressure group? My best guess is that it was 85%/90% accurate centred. Could this be the cause why the gearbox couldn't get to the engine the last 3 cm, in such a way that the input shaft was pressing the pilot bearing or the clutch plate?
Or do you know any other reasons what could cause this 3cm gap...?

Thanks for you help in advance,
Best regards,


Zijad

 

[sadam_husain]

85%/90% centred is never good enough it has to be perfect 100% centred for the input shaft to line up, you can get cheap plastic pilot tools off ebay really cheap but it would still take a couple of weeks to get to you which probably wont help you too much. When the clutch is centred properly and you line the gearbox up properly they slip together real easy, a tiny smear of moly grease on the input shaft also helps it all slide together

 

[jblueridge]

I've had this on my MGB. Even with the plastic input shaft tool it was sometimes hard to get the last bit mated.
Besides getting the clutch package centered I have to have the engine and gearbox st exactly the same angle. Sometimes giving the real input shaft a slight turn by hand can get the little change you need.
Cursing is necesary.

 

[ozcrusier]

I have never had a gearbox slip straight in there always a pain. The worst I ever struck was my old 78 Cleveland 351 f100 4x4 by my self under the truck all day pushing, pulling, cursing, jacking motor, up, down then the stinking thing just slipped in. Did you try nipping up the bolts 1/2 turn each when it was 3mm from home sometimes this works but if not pull it apart double check the clutch plate is in the right way and as above grease the spigot and be patient as it come apart so it will go back together.

 

[Aussie 25]

As said before 80 90 has to be a 100%. Take it out and check the alignment. You say you have oil on the clutch, look at the input shaft in the box, you may have oil leaking out of that seal also. I normally change them as well when I do clutches.

 

[Zijad]

Hi all,

Thanks for your advise. I will find the required tool and try again.
Btw: I tried to install a few bolts but the distance was too big. Thema I used extra long bolts but after some time too much pressure was required so I stopped.

I will let you know what the result is.
Thanks again,
Best regards,
Zijad

 

[roscoFJ73]

I've never used a tool. Just lined it up by eye and wriggled the gearbox and they slip in. You can also use a bit of wooden broom handle. But you should be able to buy a tool at any parts shop