I've been trying to install a gearbox and have spent quite a few hours trying to get the shaft back into the pilot bushing with no luck.

My assistant (girlfriend) is pretty much out of patience, and this is about the last chance to get the gearbox installed for several days.

I can get it to within about 15mm. So I'm pretty sure the I'm just not getting the shaft into the bushing.

Should I try using bolting it up at this stage to help line it up?

If I leave it all sitting for a while like a week will it be a problem (eg oil flowing out of the pilot bushing?)

If the cluth is sitting concentric to the hole into the crank then it sounds like it's just a matter of wiggling it into alignment. Is it a 5 speed?

I have to give mine a pretty hard shake and it can take a while, you will know when it goes in as it's an obvious slide into place and they come right together.

Wouldn't reccomend bolting it up until you've aligned it. If they are still separate try and spin the input shaft on the gearbox and then try again, but normally I bring the two together and then rock the gearbox (sided to side) and it slides in.

Just confirm that the clutch disc is aligned properly, so the shaft can actually go in.

If the gearbox is full of oil I use an offcut of a tailshaft wired to the gearbox to keep all the oil in. If you have a donor tailshaft, cut the input end of the tailshaft and use it as a plug to keep the oil in the gearbox as you manouvre it into place.

Did you have the clutch out because if you did the spilne may be out of center with the bush.
If you didn't, try putting your tailshaft in the box , in gear, and getting someone to turn it whilst you try to push it in.

Thanks yes its a 5speed. I've stared at the clutch for ages and it really looks aligned. I guess I'll give it another go and re-seat it if it doesn't work. Good point about putting it in gear - I'd tried wiggling using the tailshaft but I think its in neutral.

I think one of the first things I learned with dattos was to have a front shaft out of an old gearbox to line the clutch up before you tighten it and as Chris said the front off an old tailshaft to poke in the back of the box.

i learnt that from watchin gpiggy, but still dont have an old input shaft an L series here. got a old tail shft end for the back of the box. put it in gear and spin it like ivan said. ive seen it work before too.

maybe time to get a new assistant

I can get it so the splines engage (tailshaft wont turn any more) but still wont go all the way in. That's telling me that the clutch is misaligned..

Guess I'll try again with the supercheap auto generic clutch alignment tool. I'd have tear apart the 4 speed box to get a spare input shaft.

another way that might work which i have tried in the past..

loosen the pressure plate so the clutch plate can "just" be moved by hand.

slide the gearbox in all the way, pull it back out and tension the bolts/nuts.

just something else that might be worth a try

2 tips that have worked for me


Jack up the front of the motor slightly to improve the angle
and
thoroughly clean and grease the locating dowels

dont listen to weekend 1000 levey just likes to watch him grease shafts.

i remeber having to jack the a15 on an angle when we put the gearbox back on that. thought that was cause it sat 20 to 30 mm to high on the mounts