throw out bearing

[koballa]

i had to change the clutch in my 1990 240 so i did the TOB and the pilot bearing. i just took off the bearing without really looking at it put it back together and the trans will not go back in correctly the TOB is on the plate but i have 1 inch to get the trans to meet up.. at this point what i need to ask how far does the TOB go back on the inputshaft mine only goes back about 1 and a half inch i am thinking maybe a bur is keeping it from its full range but i never seen how far it slides back before i took it off so i am not sure

[PapaSmurf2k3]

have you tried spinning the tail shaft (with the driveshaft) to get the splines on the input shaft and back of the engine to line up?

If you really are right on the throwout bearing, you should feel a lot of resistance when you move the fork with your hand. Do you?

[koballa]

yes i have put the trans in ger and tried to turn the shaft it don't move so i think its started but its still 1 inch away i can see the TOB is on the plate and trying to move the fork it will not move at all so its like the TOB is not going back like it should but still not sure because i never seen how fare it went back before i started

[PapaSmurf2k3]

Yeah, that sounds very weird.
I guess all I can say is you'll probably have to pull the trans back out and make sure everything is moving correctly.
Here's a pic of how mine was when I had my engine out:

You should also check out the factory service manual.
www.nicoclub.com/FSM

[koballa]

well i got it back in.. it was the release sleeve it had a bur on it so it was not going all the way back so i just got a new one and that fix it!!