Mating engine & trans

[Forssling]

Hi All!
I have been trying to put my 901/11 trans and 2.2T engine together. The clutch is centered and I've looked so the clutch fork doesn't interfere.

Is it supposed to slide in fairly easy? I have tried to press it on with the two top bolts but it seems like it's gettin on tilted so I have not proceeded. The threads at the lower bolts are not protruding enough to get a nut onto them. They are just shy of getting out of the holes, I would guess I'm about half an inch from getting it together. It feels like a firm stop.

Anyone that has got some pointers? Appreciate all input.

Thanks,
Jörgen Forssling
Gothenburg
SWEDEN

[proporsche]

in your case you have to align the clutch bearing into the clutch for before you can marry the transmission and the engine..you have to rotate the TO bearing once you get get it together through the window on the top of the the trans.

Ivan

[proporsche]

here
911 clutch fork (Grady, Tyson, others?)

[Forssling]

Thanks Ivan, I know about the alignment of the TO bearing and fork. But the thing is when I have about half an inch to go it is not the fork that is in the way. It is still pretty "sloppy".

Does that sound right? Anything else to check? And should I worry about damaging the flywheel bearing where the tip of the transmission shaft goes?

//Jörgen

[proporsche]

Hi ..hoping you have the correct clutch disc..how did you align the disc on when you installed it?
Do you have the tool for it?.engine is out of the car or both are outside the car?

Ivan

[Forssling]

I have the right clutch disk (Sachs 1878 005 614) and I borrowed a proper alignment tool to get it centered.

Both engine and trans are out of the car.




//Jörgen

[MichaelSJackson]

The 4 bolts are the same length so the same amount of exposed thread should be the indicator that you are going on straight. The top and bottom shouldn't be different.

[eastbay]

You can put the trans in gear so you can wiggle the input shaft while inserting, might help.


If not, you just don't have everything lined up correctly, sometimes it is a crap shoot. My last new clutch disc was very tight on the input shaft and took several re alignments. Pull apart, re align the clutch disc again, may take several tries.

When it is right it slides together very smoothly

[Forssling]

Originally Posted by MichaelSJackson

The 4 bolts are the same length so the same amount of exposed thread should be the indicator that you are going on straight. The top and bottom shouldn't be different.

The bottom bolts are stud bolts with nuts, and the top bolts are regular bolts, with different lengths due to one holds the starter.

//Jörgen

[Forssling]

Originally Posted by eastbay

You can put the trans in gear so you can wiggle the input shaft while inserting, might help.


If not, you just don't have everything lined up correctly, sometimes it is a crap shoot. My last new clutch disc was very tight on the input shaft and took several re alignments. Pull apart, re align the clutch disc again, may take several tries.

When it is right it slides together very smoothly

Thanks, I'll try to wiggle some. As said it is almost in so it has to be on the splines already, and the tip has to be somewhat into the pilot bearing in the engine.

That is what make me confused, as to what is restricting it to go all the way in. I tried to do it on my own. I will get a pair of extra hands and eyes and try again.

Thanks all!
//Jörgen

[Walt Fricke]

You should be able to tell, by rotating a wheel with the tranny in a gear, if you have the splines engaged or not.

I'd not think the guide tube would bump into the TOB so as to stop the mating. But a bore scope is really nice to have in moments like these.

I don't have experience with the 911 transmission and its unique release system - but couldn't you wiggle the fork around to be sure one of its two tips isn't underneath something it shouldn't be under?

[Dauner]

May not be apples to apples as my car is an 89 Carrera 3.2 with G50 transmission, but I had the exact same problem this summer mating tranny to engine. Could get to within about 3/8 of an inch, and then no further. Clearly the spline was engaged. Tip of spline shaft not going in to pilot bearing. I was using a brand new clutch alignment tool, and so assumed alignment was spot on. Found a note buried in a thread where someone noted the cheap plastic alignment tools like I was using aren't perfect. I ended up taking a pry bar and through the window pried on the fork just a little bit to take a small amount of the pressure plate force off of the clutch disc while my 16 year old son pushed and voila, popped right in the rest of the way. We had been fighting it for hours before I saw the tip in the forum. Took 2 minutes after taking some spring force off of the clutch disc so it could "float" a bit...

Mark

[proporsche]

i would take the clutch off and see if you have the correct pilot bearing or the clutch disc positioning the wrong way..

Ivan

[Flat6pac]

Correct me if I’m out on this...
The 901/11 uses the smaller flywheel with built in ring gear and clutch package, pre 70 901 trans.
The set up clutch you’re installing is the 911/xx type, larger with the belden cable that actuated the TOB and clutch.
The factory modification of the 901 trans is the beginning of the 911 series transmission
Bruce

[Walt Fricke]

Bruce - His 2.2T originally came with the 911 pull clutch tranmission, the same flywheel as the 915, and he has a pull clutch PP for sure, and the right TOB and release fork.

Ivan's suggestions are interesting, but a) if you put the clutch disk in backward, isn't it really hard, if in fact possible, to get the PP on? b) as to pilot bearings, isn't the nose of the input shaft the same diameter? I think there was a change in the spline count on the shaft, though? Or am I thinking of some other spline change? The bolt in pilot came with the switch to the 9 bolt flywheel?

My cheap plastic alignment tool has worked fine for me, though. My rodeos have always involved getting the later style 915 release fork into the TOB when I had left the transmission in the car. I'm trying to imagine how Mark and son were able to pull on the TOB mid-install - impressive.

As a general rule, it is risky to use tightening a nut or bolt to force the two cases together.

[Flat6pac]

My point being the nomenclature of 901, 911, 915
If the trans is close and not going, all is remaining is the guide tube being wrong size.
I saw that in the G50 in the past. Maybe the wrong TOB
Bruce

[T6andT]

Different guess here. Looks like you have an aluminum plate that is bolted to the housing for the cable. Could it be possible that the ring gear is hitting these bolts?

[Dauner]

Walt, this definitely fell in to the work smarter, not harder category. I didn’t have to apply hardly any leverage and the tranny just slid right in...

Cheers,

Mark

[Forssling]

Originally Posted by T6andT

Different guess here. Looks like you have an aluminum plate that is bolted to the housing for the cable. Could it be possible that the ring gear is hitting these bolts?

Bang on the money! That was it!

I turned the bolts the other way with the heads inside the bellhousing. The PO have had another setup, possibly this trans was used on another vehicle, and the bracket for the clutch cable was cut off. I bought my project in boxes with a lot of missing parts and wrong parts.

I am so thankful to this community. Thanks all for taking time trying to help me.

Soon I can put the engine and trans into my totally restored car.

Best wishes for the, hopefully, better and improved year of 2021.

Jörgen

[proporsche]

good job and good eye ..i was wondering what was the bracket about ...fooled us all;-)

Ivan