I pulled the trans to replace the clutch and now I cannot get the trans to line back up! I am using a trans jack then two floor jacks with a 4x4 across them to support the transfer case. I am about four inches from the block and either side is either 2 inches high or low. Just wanted to see if anybody had any tips on getting it to move since it is such a bear. The truck is 1999 f250 7.3 4wd.

 

Sorry to insult your experience....but did you use a clutch alignment tool?

 

I was going to say that also. LOL

 

Sounds like the transmission input shaft is not going into the splines on the clutch disk. Did you check to make sure the number of splines on the clutch and transmission input shaft are the same, i.e., slip the new clutch disk onto the transmission input shaft before installing it?

 

clutch disk wrong splines?


clutch alignment tool is a MUST. and CHEAP.


and a 4x4 transmission/transfer case is a real pain.

 

yes the clutch came with an alignment tool that i used. I did not line the trans up to clutch before installing but I assume it would fit as it sayed online it would.

 

This is the clutch kit I got https://www.pepboys.com/product/deta...207.3L%2520Dsl

 

First I would verify that the clutch has the same number of splines as the transmission. Just because it said online that it would fit it may not. Second I would separate the trans from the transfer case, that is just too much weight/bulk to be dealing with unless you have a very good trans jack, IE professional grade, capable of handling the weight, the Harbor Freight types are not really up to the task. You are risking the chance that even if you do get it all the way in you could "spring" the clutch disc slightly and have constant problems until you replace it again. The trans must slide into the disc smoothly and squarely.

 

added tip..

get threaded rod (several) 12 inches long , and thread them into bell housing to aid in alignment as you move the transmission forward.

and yes the alignment is critical .. the last 6 inches.

splines must match up, dowel pins, bearing... all must align. then it will slide right in.

 

Can you compare your alignment tool to the input shaft on your trans? Check spline count, measure diameter, etc? Also, does the alignment tool fit into the spline hole on your old clutch plate?

It could very well just be that if you are stabbing the trans with the transfer case attached, that the weight of the Tcase hanging off the side is pulling the trans out of center as you try to wrestle it in.

 

Also, be very careful about forcing the trans onto the bell housing by trying to draw it down with bolts. It is VERY easy to break the ears off of the transmission case that way.