1997 honda civic plain Jane stock. Bought new flywheel, PP, disk set; fitment assured by vendor but PP hits shift lock bolt on trying to mate trannyCannot mate tyranny to motor. Measured old PP clearance and new. New is 1/2" too little. Assume vendor error, wrong PP or flywheel too thick, too far out from crank mating surface, but measurement of old PP, mated up to old clutch PP, disk, flywheel is the same as new. So assume new PP is wrong. Your comments?

 

If you already measured the pp and the disc why haven't you measured the flywheel?

 

You need to read. I measured from pilot bearing upper race to Flywheel /clutch disk mating surface. Both the same.

 

You probably don't know what you're doing because a 5spd does not have a shift lock.

 

Apparently you have never worked on a 5 speed since they have an "Interlock Guide Bolt" per the official manual, which is located inside the transmission engine side bell housing. You cannot remove the mainshaft, countershaft until you remove this bolt. It has a wide flat head with an inset hex type boss. Please refrain from exhibiting your ignorance.

 

The flywheel may not be all the way on and flat down against the end of the crankshaft (because the pilot bearing is not properly in its hole). If it's not that, clearly you must have a wrong part. Disassemble and measure each new part next to the old one.

 

So now its an "interlock Guide bolt". Either way it has nothing to do with why your transmission not getting mounted to the engine.

 

what the hell is an INTERLOCK GUIDE BOLT? Perhaps, I should just trade my Del Sol for a Prius. LOL

 

What brand pressure plate and where did you get it ?

 

The Interlock Guide Bolt locks the shifter plate which guides the shifter forks as they move. Actually the end of the bolt is like a pin which fits in an oblong groove in what the shop manual diagram (pg 13-11) calls the "Interlock" or shifter plate. I only mentioned this because this bolt protrudes out from the transmission slightly and it's the part of the case which comes closest to the pressure plate. In my case the pressure plate was rubbing on this protrusion preventing mating. Upon further measurements it turns out that the PP I am attempting to install is 17/32" higher than the original and therefore cannot fit in the transmission bell housing. It's an ebay item from clutchAmerica. I contacted them to see if they can supply the correct PP.

 

Wouldn't hurt to take a couple pics showing spec details and sending it to the seller so they can verify what they sent you was correct or incorrect and get you something shipped out.

 

Suspect supplier = suspect parts. Use a quality product from a trusted source... it may cost a bit more, but you won't have the headaches that you are experiencing now. Your time and stress have value... I hope that ClutchAmerica can make things right for you. If they inadvertently shipped you the wrong pressure plate, they should send you the correct one. If they are adamant that what you received is correct... it ain't gonna work and you have learned a valuable lesson on who NOT to deal with.

You KNOW what the problem is... there is nothing anyone here can do for you now. You need a product that fits. If they cannot provide it, find another supplier who can. Please post your outcome when you get there... maybe it can help someone who experiences the same issues in the future.

Good luck.

 

Took tranny out, measured carefully. Old and new parts seem to measure the same. New clutch disc is thicker.
Easy way to lock mainshaft so as to rotate tranny or engine to facilitate alignment?
Going to dress mainshaft spline tips for more clearance, easier alignment. Same for the mainshaft tip going into the pilot bearing. More bevel.
About how far above the plane of the transmission mating surface does the end of the mainshaft stick out? Mine is about 1//2 inch
About how far apart would the trans/engine be when you can be sure that the mainshaft splines are fully engaged with the clutch disc?
Any preferred location of that smaller machined hole between two of the flywheel bolt bosses?

 

Don't grind anything.

Try the new clutch disk on the transmission shaft to make sure it is the right part. Of course the new disk is thicker that's the whole reason for replacing it. The overall height doesn't change though because the cover pressure plate will be tightend down flat against the flywheel no matter what the disk thickness is.

It's important to have the clutch disk exactly centered over the pilot bearing. The silly plastic tool isn't very good at that. Get your head down there and look in the hole to see if its concentric. Also you can examine the edge of the disk relative to the pressure plate it should be even all around.

The splines engage at about 1 1/2 inches apart then the pilot bearing about 1/2 inch. You can rotate the crank by hand to try to get it in better line. Do not force it with the bolts. Some people use longer bolts or cut the heads off of spare bolts to help hold the transmission in line.

 

I just use a transmission jack.

 

Thanks for those measurements of engagement! I did mount the pp/disc to the flywheel off the engine and slid it on to the output shaft. It went on easily and bottomed out against that collar surrounding the shaft without touching anything in the bell housing. Seems normal.
Today I will make a sling since I do have rafters overhead.
Nobody responded to how to lock the tyranny but I think I can stick something in the speed sensor hole and lock the diff.

 

because we never had to lock anything when changing out a clutch....