urgent help Surf manual conversion

[J_Dub]

alright im half way through replacing the fcked auto box in my daily driver, Surf 3ye.
Just wana double check a few things
*I replaced rear main seal.. That simply just slots into place yea??
*When I removed auto flexy plate there was a washer spacer behind that, this does not go back in right? as its a spacer because the flexiplate is a lot thinner than the flywheel going back in?
*do i just reuse the dust cover (gasket between bellhousing and block) that was on the original setup? I dont see why not, but the flywheel only just (by a hair) brushes on 1 part... could be just dirt and shit on flywheel.....????
*and how the feck do ya get the clutch dead centre before tightning up pressure plate.....???????
any help be MUCH appreciated as wana get box up and bolted tomorrow, im ready now, flywheel and clutch are in but wana confirm those things before i bolt in box.....

[nstacey]

and how the feck do ya get the clutch dead centre before tightning up pressure plate.....???????

You need a clutch alignment tool


When I did my clutch I used an old imperial one that my dad had and wrapped it with tape to get the right thickness for the bearing and clutchplate

[haynzy]

I just sight mine, get em every time

[J_Dub]

I just sight mine, get em every time

thats what im hoping for

[meatc]

Have a hunt in your parts bin for a peice of round (even dowel) that fits in the spline of the clutch plate and round the end of it so it centers in the crank.

Dont for get the crank bush that you want have from the auto too.

[J_Dub]

Have a hunt in your parts bin for a peice of round (even dowel) that fits in the spline of the clutch plate and round the end of it so it centers in the crank.

Dont for get the crank bush that you want have from the auto too.

crank bush????????
so is everything else ive said ok?

[Heath]

Have a hunt in your parts bin for a peice of round (even dowel) that fits in the spline of the clutch plate and round the end of it so it centers in the crank.

Dont for get the crank bush that you want have from the auto too.

crank bush????????
so is everything else ive said ok?

Little bush / brg the end of the input shaft goes into in the centre of the flywheel (I think )

[meatc]

Little bush that goes into the end of the crank that the end of the gearbox input shaft then goes into. Done as the two can rotate at different speeds and unlike an auto where the inputshaft is supported by the flexplate etc the manual one is unsupported when the clutch is disengauged, so it get assistance from the crank hence the bush.

Should be easy to get (maybe not on sunday though)

[J_Dub]

will check my parts box that the kit came with. cheers. everything else seem ok?

[meatc]

Just re read your original post. If the flywheel touches the dust plate you may want to compare the flexplate and flywheel for size. If they are different (some are some aren't) you will need a different starter motor too.

seal should just come out from the back and new one in.

If you bought the manual swap as a second hand kit chances are the bush wont be there. They can be really hard to get out of the crank. Ripco etc should have them.

You wont need the spacer but will need the flywheel bolts as chances are the will be a different length to the flex plate ones.

[Heath]

A trick for getting them out is to find a bolt/rod that just fits into the crank brg and fill the cavity behind the brg full of grease. put the bolt/rod into the hole with a rag around it and covering the bearing (might pay to get a couple to catch any grease that gets spat out) and hit the rod/bolt. The hydraulic preasure should force the brg out.

[J_Dub]

alright will have a nosey tommorow
and try repco if bearing isnt there

[J_Dub]

well i figured what the bearing was called that i needed.. spigot bearing i knew that
got manual box up and in but it isnt slipping into place, bout an inch from seating in place, all square and level using the eye but just cant get in to slip into place.
Any hints or tricks????
otherwise looks like i gota slip gearbox back and find a clutch alignment tool and make sure clutch is dead centre.
fcuk it

[meatc]

Arh ignore my PM I hadn't read this but good to hear you sorted the spigot bearing.

With the box try slecting a gear and turning the output shaft a bit as you jiggle and push. It could be the splines aren't quite lined up.

[J_Dub]

Arh ignore my PM I hadn't read this but good to hear you sorted the spigot bearing.

With the box try slecting a gear and turning the output shaft a bit as you jiggle and push. It could be the splines aren't quite lined up.

yep went to try that then realised.. fcuk.. gota cut some of the trans tunnel to suit the gear sticks, figured the hole would be 1 standard size to suit all boxes from that model.. guess not.
'Cheers for your help ay mate