Transmission Torture

[stygianumbra]

I have a 1991 300zxtt 2+2 conversion 5sp, I spent 10 hours today putting in a rebuilt transmission and troubleshooting why after everything went pretty smoothly the starter seemingly would not engage the flywheel teeth completely. The car has been sitting 8 months and the battery was stone dead sitting on a wood block.

When I try to start the car all I get is a "grinding" noise, on closer inspection it seems the starter doesn't fully "extend" into the flywheel just the tips. So far the only thing I can think of is the battery is totally gone, it barely holds a charge and might have dead cells. I am bringing a fully working one tomorrow to test this theory but I am asking for others ideas. Could a seriously messed up battery cause this? When it was parked the starter operated fine, it has been cleaned up and kept safe since then.

I have rocked the car in first and reverse, the fan on the motor spins with no odd noises coming from beneath so I am assuming the flywheel isn't binding. I also have had my friend push the car while in gear and check that the clutch was disengaging completely which it was and popping the clutch will turn the motor over. I installed and torqued the transmission in the pattern according to the service manual.

I have no internet there unfortunately so I am limited by what I remember. The only parts replaced here are the transmission, clutch release bearing&sleeve, needle spring, clutch fork dust boot, and bronze shifter bushings.

[car nut]

You wouldn't happen to be using an NA flywheel with a TT bellhousing would you? The NA flywheel is smaller than the TT flywheel, which would be the reason that your starter teeth aren't fully engaging.

[stygianumbra]

It is definitely a TT flywheel and it might be a NA transmission, I can't be sure but the tolerance on the flywheel to bell housing is very tight. From reading all over it seems shot battery, needing 16 gauge/2mm shims for a na transmission, or bad starter are the only possibilities. I don't know how to tell them apart though whats the average/minimum safety spec for flywheel to bell housing clearance? I think this is on the high side of 2mm off maybe 3 doing it from memory.