When i did mine i had a similar problem. I ended up pulling the tranny out and rechecked the clutch alignment. It was slightly off, so i reset the clutch with that alignment tool. Once i did that, she went right in.
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I ended up getting it at Checker. They actually had to take one out of a '97 XJ clutch kit (the ones that come with the tool). They almost didn't let me borrow one from that kit (which I could understand why), but these guys at this store are pretty cool. I told them that I would only need it for about an hour. So, they let me borrow it. The funny thing (kinda funny) is that on this day it was raining like a *itch outside. I had to re-align my clutch in the pouring rain. I had it done if a couple minutes, re-torqued and all. Then the tranny slid right in. I took the tool back all cleaned up.
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Originally Posted by silver03cobra View Post
* the alignment pins on the bellhousing (or on the block, depending on where they stayed during separation)
* the input shaft / clutch disk splines
* the input shaft length
* the pilot bearing
You can verify all of these by measuring with the transmission off. Or you can test fit things to rule out issues.
1) Have you slipped the clutch disk over the input shaft to verify it fits without sticking or binding?
2) Have you test fit the pilot bearing on the end of the input shaft?
3) Have you checked that there isn't something behind the pilot bearing that is preventing the input shaft from seating all of the way?
4) Have you test fit the bellhousing without the clutch/pressure plate installed to verify the shaft is not too long or pilot bearing issues?
It sucks that it's giving you so much trouble, but there must be at least ONE thing that is not right. we have to narrow it down by proving everything that you can and see what's left.
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