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FJ20 Gearbox / Clutch Issue - Help needed

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    #61
    not to be bearer of bad tidings, but the second dowel being a sleeve around a bolt is probably no good.

    The reason is simple enough, if the thing is off centre, you need to run up offset dowels on a lathe, to move the box in whatever direction and distance it needs. That's a pretty tall order on a sleeve, but a piece of piss with a solid dowel. just start with a dowel too big, and machine one half down to the right interference fit, then alter it's position in the lathe (cue McDodgey here - you could use a shim, or just adjust a 4 jaw chuck to get it spot on) and slowly cut the opposite half of the shank down to fit.
    John McKenzie

    Science flies people to the moon.
    Religion flies people into buildings.

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      #62
      I think he is suggesting the reason it isn't lined up is cause it is missing the dowel.

      If that is the case then happy days. Install the dowel, crank up the indicator again and happy days.

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        #63
        Extract from a 200SX how to guide when replacing the gearbox.

        "Check throw-out bearing. I'd try to describe exactly how it should be but there's little clip things and I'm sure to f*ck it up. The workshop manual has a decent diagram, look at that.
        Check dowels - make sure the dowels are still in OK nick and give them a quick file if needed. The dowels should go in the engine side so you can hang the gasket off them, one is at 12:00 and the other at 9:00. Make sure the gasket is in position before you bang the dowels in, it will not stretch over them. "

        The 'gasket' referred to would be the sandwich plate I assume.
        Richard's DatsunZ lappin LakesidZ http://www.youtube.com/watch?v=47OSh...&feature=g-upl

        “Freedom of speech does not protect you from the consequences of saying stupid shit.”
        ― Jim C. Hines

        “Everyone is entitled to his own opinion, but not to his own facts.”
        ― Daniel Patrick Moynihan

        “Four hostile newspapers are more to be feared than a thousand bayonets..”
        ― Napoleon Bonaparte

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          #64
          So I spent another 10 hours putting it back together. Stubborn POS car.

          The noise I was experiencing has pretty much gone.

          When pairing the engine to the box, the input shaft was VERY snug on the spigot bush in the crank. I gave it a quick once over with the dremel to give it more clearance. The dowels all lined up fine.

          My replacement clutch/flywheel setup seems to be working nicely and the throw-out bearing/ clutch slave seems to work a-ok straight off the bat.

          I don't think the alignment is 'perfect' but it's as good as I'm capable of getting it.

          The new gearbox shifts really nice (Redline Heavy Shock-Proof FTW), and is quiet on the highway. I did around 150kms last night no issues at all.

          Thanks for your assistance everyone.

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