i'm trying to put my tranny back on after changing my clutch

its an 87 iroc, stock 305 motor with borg warner t-5 tranny. new clutch from autozone, the clutch kit didnt come with a pilot bushing so i got it seperate for like 5bucks

i've been trying for the last couple days it just wont fit in, the splines match up no problem but it wont even get up to the guide pins on the block

i tooka look at my old bushing and eyeballed it to the new bushing already installed on the block, and it seems like the old bushing is larger
i put the old bushing on the input shaft and theres alot of play, so i think the new bushing i got isnt the right size

the new bushing is a dorman part, #14650
it says od .594 and id 1.094 which doesnt make sense to me but ok
and a depth of .746

is it the wrong bushing or something?
or did i just do something wrong

 

Old bushing has a lot of play cause it's worn out. A new bushing should fit much tighter with only a few thousands clearance. Q: you didn't bugger up the end of the new bushing when you installed it? This would close it up a little.

A lot of times there will be a slight misalignment of the tranny centerline to the bushing center that prevents tip of input shaft from going in on install. In this situation I like to have someone push in the clutch pedal so the clutch disk floats and allows you to align tip.

OD = outer diameter, so that would be the outer portion of bushing. ID = inner diameter, that would be the size of the hole in the bushing. Depth is how long the bushing is.

 

i dont understand what u mean by bugger it up
i used a bushing driver to install it
but in my first attempt to install the tranny i accidentally knocked the whole crane over dropping the engine and tranny (gotta know when to stop pushing) i inspected the bushing after this incident and the input shaft made a little mark in the new bushing

i'm gonna go get a slide hammer again with the pilot bushing tool to pull the new one out and test fit it on the input shaft see what clearance i get
and probably turn the bushing around when i reinstall it for what its worth

as for the od and the id,
i knew what they stood for, what didnt make sense is how the outer diameter is larger than the inner diameter, i guess its measured differently

i used the clutch alignment tool and i felt confident everything was in place, there was no play with the tool when i installed the clutch
the motor is out of the car, obiously making my initial blunder possible
and thus making use of the clutch hydraulics, more work than desired

i got the tranny close enough to start threading bolts, but i didnt wanna use the bolts to bring the tranny in for fear of breaking something as i've heard from many stories in the past

on a side note, my tranny is held in my 6 bolts, i noticed the block has a 7th bolt on the top that my tranny cant use, is that bolt hole for the automatic tranny?

 

Did ya use a pilot shaft to line up the clutch with the bushing?
Did ya try it without the clutch in place to see if the input shaft would fit in the bushing?

 

If you don't use a driver, it mushrooms the bushing and closes up the hole. You used a driver so no problem there. Good call on not using the bolts to pull it up, guys have broken tranny ears doing that. Happens on automatics too when converter isn't fully seated.

Those plastic clutch tools are just to line up the clutch enough so tranny splines slide in. But many times it doesn't align it precisely enough for input shaft to slide into bushing. That is why I recommend working the pedal to float the clutch plate to allow it to center. Obviously tough to do out of the car.

Sounds like you bolted tranny to bellhousing and are trying to bolt up bellhousing to block. I like to bolt the bellhousing to the block 1st, then bolt tranny to bellhousing. But I usually bolt on manual transmissions in car, so it's easier this way.

Just thought of something you could try, you're going to need a buddy. Disassemble tranny from bellhousing. Set both aside. Remove clutch assembly. Check input shaft into bushing. If ok, reinstall clutch assy onto flywheel with clutch cover bolts loose. Use the tranny itself as an alignment tool while buddy tightens clutch cover bolts. Bolt on bellhousing, bolt on tranny.

 

Good idea about fitting it with no clutch....

 

i'm gonna go rent the pilot bushing remover again,
i dont like the idea of disassembling the clutch and flywheel again only because i work with greasy gloves, it took alot of care no to get grease on the clutch disc

i will test fit the bushing on the tranny input shaft, and removing the bellhousing to use the tranny as an alignment tool sounds very bulky
my helping hand is my scrawny brother, i guess i'll just make him suffer

thanks for the replies, i wont get a chance to do this till friday
but if i dont succeed u cant bet i'll post right back here

 

Don't remove the bell,just the clutch and put it up there. If it goes together with no clutch it's an alignment problem.
Ask around and see if anyone has an old tranny input shaft ya can use to fit and align the clutch to the brg.