1993 KA24E D21 Truck Transmission installation trouble

[development1]

Hi!,

I am on the downhill stretch of installing my transmission in 1993 Nissan D21 Hardbody pickup, and I am having a lot of trouble forcing the input shaft into the copper bushing. I have one guy spinning the crankshaft, and another wiggling the transmission into place but it is not budging. I removed the transmission for a better view of what is going on. Apparently the shaft is engaging the clutch teeth, however, the tip of the input shaft is covered with copper fillings (The busing is new and was hammered into place with a hammer and socket). Is there anything I can do to force the transmission into place?

[Rev_D21]

Those pics are really small. Are the splines on the shaft lining up with the splines on the clutch? Are the splines clean so the clutch does not hang up on the input shaft?

[Warped161]

Those pics are really small. Are the splines on the shaft lining up with the splines on the clutch? Are the splines clean so the clutch does not hang up on the input shaft?

did u click on the pics? they get bigger

[Rev_D21]

They became big red X's for me.

[development1]

I figured it out, thanks!

[Big-Bird]

FOR ANYONE ELSE THAT COMES ACROSS THIS PROBLEM:

When installing the clutch and pressure plate make sure to use the correct alignement tool. Also check that the 'bronze' pilot bushing is the correct diameter for your transmission's input shaft (IE Test fit).

Take some emery cloth and make sure the input shaft that rides on the bushing is clean and free of burrs.

Devel: Post what you did to fix it.

[development1]

Well with the Luk input shaft bushing it has a finished side and an unfinished tapered side. I ended up installing the bushing with the tapered side facing the clutch and transmission, therefore it was hard to line up. My bro came up with the idea of taking the bushing out; we then released our mistake and reversed the side with the right side facing the clutch and transmission. We then spun the crank with a 27 rachet, and wiggled it in within 10 minutes. The clutch alignment tool had nothing to do with the problem it was the input bushing and us not realizing that Luk had a finished side and a unfinished side.

[nismopu]

Yes, this is a huge problem with ALL of Nissans manual setups. Toyota had the right idea IMO, a real bearing and only one way to put it in, lol! Also, the input shaft bushings are ALL the same diameters for all nissan RWD transmissions, I don't know much about the FWD ones. I would imagine they're the same as well too though.

fs5r30afs5r90afs5w71/a/b/cfs5r50aAll identical input diameters and lengths. peace.