Problems fitting aby engine to cdv 5 speed box

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    S2Forum Maniac
    • Jan 2008
    • 931
    • Country: United Kingdom

    #1

    Problems fitting aby engine to cdv 5 speed box

    Hi guys,been having a bit of bother mating my aby engine to the current box in the car.
    I can't for the life of me get it to mate up,now either I'm being stupid or something is a miss,never had this problem before
    It's an aby engine,7a flywheel and aan clutch,I've made a new slave pushrod to compensate for the slimmer clutch assembly.
    Is there any size/depth difference between the input shafts on 5 speed boxes?
    Also worth mentioning I've already shortened the dowels on the block.
    Any help would be appreciated,even if it is along the lines of "you're stupid,try harder"
    It's a love/hate relationship with the S2,i love it,it hates me
  • Bowie69
    S2Forum Fiend
    • Nov 2013
    • 2676
    • Country: England

    #2
    Have you measured the depth between bellhoising and release bearing and between back face of engine and clutch fingers and compared?

    I am assuming you can get it into the pilot bearing OK...
    Did you align the clutch before trying?

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      S2Forum Maniac
      • Jan 2008
      • 931
      • Country: United Kingdom

      #3
      I'll measure when I'm back up there,spat my dummy out for today,yeah I used a proper clutch alignment tool,it goes past the release fingers and stops around 10mm short of mating up flush with the block,with the clutch assembly being fairly low profile I can't see why it would foul the inside of the box,hence the query with regards to the input shaft lengrh
      It's a love/hate relationship with the S2,i love it,it hates me

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        S2Forum Maniac
        • Jan 2008
        • 931
        • Country: United Kingdom

        #4
        To answer my own question....yes I am indeed stupid,
        pulled the clutch back off to take a better look at everything,tried to slide the friction disc over the input shaft and it was really difficult,turns out I must have clattered the leading edge of the splines causing the input shaft not to go in with any degree of ease,cleaned the splines up with a file and it slid straight on
        In my defence I'm still recovering from a broken hand so I've got one and a half hands at the moment which makes wrestling engines trickier than normal!
        It's a love/hate relationship with the S2,i love it,it hates me

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        • Bowie69
          S2Forum Fiend
          • Nov 2013
          • 2676
          • Country: England

          #5
          Good find, good luck getting it finished!

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