Can not align/bolt up transmission

[Roysneon]

So I have this m52 and zf trans, s52 clutch installed, put the clutch in with the side marked "gearbox" facing the trans. I get the input shaft at least partially into the clutch splines but it will not go on any further. I have about a 1 1/2" gap. I've tried tightening up what bolts I could get started to pull it together, it was resistant to the point I didn't want to push the issue any further.

Think I just need to clean up and grease the input shaft? I mounted the clutch with the longer splined portion facing the engine.

[jlevie]

Did you use a clutch alignment tool? The likely cause is that the clutch disk is not aligned with the pilot bearing.

[Roysneon]

Used the alignment tool. My money is on the bearing, I tried to remove but did not have the proper bearing puller.I'm thinking I misaligned the pilot or have it partially pulled out.

[jlevie]

You could have pulled the pilot bearing partially out, but I can't think of a way it could be misaligned.

I don't know what alignment tool you used. I've had poor experiences with the molded plastic parts as they aren't a precision fit in the splines in the clutch disk. The pro type tools, made of machined metal, or an old transmission input shaft works every time.

[Roysneon]

Yes, it was a borrowed molded plastic tool. I will try to fully seat the pilot and re align the clutch disk with a more careful eye tonight.

[Roysneon]

Turns out the input shaft was just a very close fit and needed some persuasion to go into the pilot bearing.