The second task I undertook today was to mate the motor to the transmission. First, I securely clamped the motor to my workbench (makes torquing the clutch bolts to 80 ft-lbs much easier!)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTrG2GKYhKqF7xqsv8ygo_Q-eE_JG6a7Y5f2cJ4cG5dRGfC_r9XquWzs_VhFubC3UROCW89Gw4xO5dDKUIzwpQVPidPjvK7vbbRLyRUWqthCiwqpwoXFQkoKyHZ9Ne7teH0wS446gi2DY/s320/clamp.jpg)
After much trial and error, I got the flywheel securely mounted at the proper distance from the mounting plate (first try was too far out; second try was too far in; third try was just right). You can see the felt washer peeking out from inside the crush ring - it gets really crushed...
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbTQSzKF6p4xQvscbXsBnJJABRtPetMoBj6LjEKImCgOeyZ5ymGXYCoJWE4i1ReKqIvr4vnObHrIjNa0VanYKiq91Fg0NzqChoqP6Zt2DcxX_7hNdjtV0Pffr18tnWtyExr7SbYGSOdgo/s320/Flywheel.jpg)
Clutch pilot tool inserted and clutch mounted
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjS1pND95AVWnqZmhaoJn9aZa8LuAJSI3Bl5TEOieg0V28B1qejIfMJNpkR44MdZGkXOHOoU1dD7Bhw6rBREefZrpWloBI7iX9koluSuspqy7d1EF5PYC9qFyGxOVhNKP_O5RbcieAce4M/s320/ClutchPilot.jpg)
Pressure plate mounted and secured. After this, you remove the pilot tool.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivO-_r2cGgwk73X3acmf3R2GM5SdmBRkBiYwELE216QHGbS-WhX4djWmVrKaX5I2cfh58b62_XqyJXwgI4nHQSm0KEqvd8LmcAUQzWgYBJ_yeG9NF7D9WymTOcUUmuFLta3Yvz8CQfXe8/s320/PressurePlate.jpg)
I also rebuilt the throwout bearing assembly. Not pictured, I replaced the throwout clips, the ball socket, cleaned everything thoroughly, and then reassembled (appropriately greased, of course!)
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKwqR0nadKHpQjFJKk1Jaa6I3wn08mGjT9Oy2MJ4G7YIQZAeUgwPmt_lB3jxNNsW_h5C3C50FJ3n4AGoZdRK3yCwvoAL7EKW8GCbJGtmpVSgxHRjeKKaU-JEzZIzQKSZexs3-0T7pUGVY/s320/Throwout.jpg)
I then put both transmission and motor on rolling dollys. First try: engine was way too low:
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO70mKPgVFx2HFB5nusspVensIQMe1NBnMfd7NI5E7hjiP7fN2AxlGMhn_RM-n1FfBtM7zb63A4iTiBPnTiOjBVgKwh-A0u1godptC86pjM5-k5ICqtn3YheeJgpKf8Y28LzJuZu1_vOU/s320/FirstTry.jpg)
So, I shimmed the motor up. It *almost* matched, but you could tell something was not aligned internally. I peeked in through the little "windows" (and shined a flashlight in through th starter motor hole) and this is what I saw: the pilot bearing was just a
little low, but low enough that it did not mesh. So, more shimming ahead:
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ1fniUA8AX5kQqPfRI7QoB_cqQvnWYC6WWM9mrSjAT32BUex8eOZ1WBE2nOTUoSii6fRNUj6LQqLTcUdy4CXTfj_vG458OBHCMXsmbE0yStTQPB2BcX1uebIn8gNiPJHGYCpBvl0TyxI/s320/SecondTry.jpg)
After getting it all aligned, here it is (no bolts attached yet):
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg73Ck2SDH_7tW_vbBqpNoH4cP2KfrgAQuwbK52Mfzoufun4__47i9EaHYDk8-jpCFKRh4upNreCece2AacSqrVkUclqO1qLEUxACASNqO4T3iWSG-fjQdvEddxfXtae2kVEeWG3CKs8EA/s320/Success.jpg)
And the final bolts in place (the three bolts that don't go thru the starter blockoff are about 16mm too long - they are 100mm and standard parts are 84mm. 100mm is all I could find at the local HW store - I lost my originals somewhere... I may cut off the excess length of these before I mount it in the car. I also transferred it to a single dolly, in anticipation of getting the car back and mounting the assembly inside the car.
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgwmyiIGBN0GwXQom3X_f72KEu3ZrLb_DXc2p3ilfrIXCpmi5NB6vca4DtmFKqXGsQo51nCdRlmyRLlxlOke7rryEzZkvUNfngfTnuabDxMdIexPHxRFq2ajk4PtCh0bsjj16M9D5CJNLE/s320/Complete.jpg)
So, summary:
- Make sure you have the motor firmly clamped
- If you're rebuilding your throwout bearing, use a Dremel-type device to carefully shave away the ball joint bearing surface.
- Have two furniture dollys and lots of spare scrap lumber (for shims) for the final assembly
- You can look in through the little trapezoidal "windows" as you assemble to check for alignment of the main transmission shaft and the bearing
- Don't lose your original bolts. Ahem.