in the process of doing a clutch swap.and for the love of god I can not get the tranny back on?
the one thing I think is weird is the alignment tool for the clutch is smaller then the hole in the engine,so its like a guessing game on the alignment of the clutch disk
something is definitely not right! ive done several clutch jobs and never had a issue like this,any thoughts,something im missing>,lol
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alignment tool should not be a "loose" fit really. but it should pull in and out just fine. It should fit into the crank though ?

 

Did you match up the disks on the floor to see if they were the same? On tractors the bell housing and tranny are the main frame. Somtimes you just have to let every thing back down realign and try again after a break. One takes hours and the next slides right together for no apparent reason. Hopefully you know to use a socket on the crank pully to rock the engine.

 

Apparently you have never done a clutch job on a Cobalt.



OP, put the trans in gear, put down your purse, lift and shove. Rock it fore and aft while wiggling up and down. It will slide. Sometimes having some one push on the gear set cover helps.

 

Apparently you are Richard Head.

 

Nope, not an Irish play writer.
Thanks tho.

 

Some of the ecotec alignment tools out there that come with clutch kits are completely wrong. The crankshaft shank on those incorrect ones are only something like 5/8" instead of 3/4" (I forget the exact size off the top of my head so those might not be exact numbers, but you get the idea) so it makes it virtually impossible to get a dead nuts straight alignment. If you still haven't gotten it back together again, you'll either need to get your hands on the correct alignment tool, or mod the one you have to fit correctly.

 

Lmao. It seems you think everyone has a purse lately

 

Be VERY careful doing this. Considering he has the incorrect alignment tool, he can and WILL damage the splines on the clutch disc if he gets too aggressive with attempting to align things up. Once that happens, the input shaft will never slide into the disc without taking a file to the disc splines, even if it's perfectly aligned. As a matter of fact, I can almost guarantee that his clutch disc looks a little something like the pic below at this point.

This is what happens to a brand new disc when coupled with the wrong alignment tool....



It might not look that terrible in the pic, but the tolerances are tight enough that the disc will absolutely not slide over the input shaft with that damage.

Here is also a pic of the incorrect ecotec alignment tool, and what ultimately needed to be done in this situation to make the tool work "correctly".

 

We had one with bad splines from the factory. As bad as this sounds, it worked. Put the disc on the trans backwards, large socket over it all, and beat it on with a hammer. Fixed the splines and then the trans went right on.


I feel you on the clutch kit tool. I have like 3 that are too small.