Reinstall of Ka24de help 911

[240sxOwner]

I recently bought a used engine from another 240 owner and i am now reinstalling it....everything has gone to plan but the output shaft from the transmission won't slide all the way into the engine. I just unbolted my engine from the transmission to remove it and i was going to do the same to reinstall instead of dropping the transmission. What should i do? How come it won't slide the rest of the way in...it has about a 1.5 inch gap, and won't budge

Thanks

[NISTECH]

rotate the crank pulley on the engine a little bit.

[240sxOwner]

i have tried that...but i will try it again today since for the first time during my whole engine swap process...I have someone to help/assist me...lol

[240sxOwner]

Ok....i tried that for about 4 hours or so and gave up. We pulled the transmission, completely out of the car. Realigned the clutch, and tried to put the transmission and engine together with nothing in the way. The splines are matching now because when we turn the crank, the driveshaft spins also. There is still a 1 inch gap between the transmission and engine....WHAT on earth can the Problem be. Im starting to think the devil has some personal issues with me....

[NISTECH]

Pilot bushing maybe undersized[mushroomed from hammering it in?

[240sxOwner]

I got the pilot bushing straight from the dealer and i used the back of a socket to knock it in...it is in perfect condition...I just want it fixed so i can drive my car...it has been down for a month now.

[NISTECH]

perhaps the alignment dowels from the used engine are in it and the aligment dowels from your old engine stayed in the trans and they are butting up against each other. If you got the clutch lined up properly and didnt mushroom your pilot bushing you should have no problem sliding it in to the engine once your get to the 1 inch gap your talking about unless what I mentioned about happened. I assume your actually sliding the engine into the trans with a engine hoist?? rather then putting the trans into the engine setting in the car? If so have some one crawl under the car and have them lift and lower the trans a bit while your wiggling the engine hanging from the chain on the hoist.

[240sxOwner]

can you verify the part number for me 32202-B9500

[NISTECH]

I have no way to verufy a part number today I am not at work.

[240sxOwner]

i verified i with 2 different dealers. They also told me to put the transmission into gear and wiggle it in...i was also told to put some bolts in to suck it in a little bit then try wiggling more. They told me that a few teeth might not be matching perfect and the just needed to be seated. Any ideas? Thanks for the help

[NISTECH]

i9f you have tried all that has been recommended from me and from what the dealer told you I have to wonder if maybe you dont havt the throw out bearing installed properly on the fork? It is difficult but with the tricks listed you should have gooten it on. did you check to see if the dowels were there?

[240sxOwner]

which dowels are you talking about? I haven't located any...where would i find them? Im calling out of work tomorrow to work on it, cuz i have to get this thing running

[NISTECH]

they are usually at the side near the bolt in the center of the bell housing. they line up the trans and engine so you can put bolts in.

[240sxOwner]

oh...i thought you were talking about others...no, there is only one i believe and it is at the very top of the engine...the same one that the rear plate sits on. Is it possible the clutch is still not aligned correctly?

[NISTECH]

is there a sleeve typ dowl around one of the center bolts where I was mentioning some times it will stay in the trans when you pull the trans out. If you are putting another engine in it is possible that sleeve dowel is still in your old trans and it is butting up against the sleeve dowel in the new engine.

Yeah if you did not use the proper clutch alignment tool your clutch could be out of line. When you install the clutch disc and pressure plate you leave the tool in till the pressure plate bolts are torqued down. then you should be able to slide the alignment tool in and out of the pilot without difficulty. If it is very hard to slide it in and out you need to loosen the plate and adjust it so it will. If thats all good then your trans input shaft should have no problem sliding in there.

[240sxOwner]

Ok...i have it all in the car now and everything is hooked up. This is what i have when i start it up. Water leaking from around the top of the intake manifold, at the no. 1 cylinder. Smoke from the exhaust, and at the downpipe/exhaust manifold flanges. Idles very bad and takes a good second to realize throttle position. Try and help me out the best you can. It runs, but not well enough to drive yet. Thanks

[gumby]

oh god this is making me cringe

[NISTECH]

trace the water leak and fix it. The smoke from the exhuast may just be normal burnoff of foreign material[oils and such burning off] If that water thats leaking is fronm the intake gasket it could be entering the #1 intake runner and effecting the quality of the idle. try to locate the source of the leak first and fix it. then recheck idle quality.