Ladies and Gents,

I have a 96 Bronco with a 302 - 5 speed manual trans. My father and I are trying to put in a new clutch/flywheel and have the following completed: drive shafts out (front/rear), transfer case out of truck, transmission bolts (6) out of trans/engine, and cross member out of truck. We have a trans jack under the trans and a come-along pulling from the rear of truck attched to the trans because THE TRANSMISSION WILL NOT SEPERATE FROM THE ENGINE BLOCK. This is the most frustrating thing I have ever dealt with. We have tried to lube up the dowells and give the trans a few good whacks with a rubber mallot - and still for some reason, the trans will not separate from the engine. I know it sounds like there are still bolts in connecting the two, but we have removed all 6 (2-top, 2-side, 2-bottom). My father and I are at a loss for what to do. The Haines manual doesn't show any pictures or any description to do anything differently. Help/Advice would be greatly appreciated!!!!

Justen

 

tried a pry bar yet?

 

Tried it, but wanted to be careful to not damage the bell housing or the block

 

So can we assume there is no visible separation at all? Not even the beginnings of a gap between engine and transmission? Assuming starter is out. Have you tried slipping a blade between the two units. A putty knife or even something as sharp as a utility knife to break or scrape away any corrosion that might exist between them and be holding them together?

 

Wrap a mace with some cloth (this will be heavier than a rubber mallet) and hit the housing near the engine. Try not to damage anything.

 

starter is out, we have tried crowbars, puddy knives, lube, so on and so forth - we have a little seperation on one side, but not on the other. The seperation that we do have is VERY minimal. I just want to verify that there are only 6 bolts mounting the trans to the engine - are there any bolts that we possibly have missed (maybe at the top of the trans or engine) that cannot be seen to the naked eye. My father and I are really at a loss here. There is no way that any type of corrosion or rust would cause it to be this difficult.

 

You don't happen to have the trans jack up so high as to have the trans against the body do you? Just asking. If not is it possible that the input shaft on the trans is siezed in the clutch plate? I helped swap out a clutch in a 76 cj5 that this happened. It made it a real pita. In our case we were able to seperate the trans from the bell allowing us to twist and pry. But on the 5 speed they are all one piece I believe so this can't be done. I would try pulling from the rear and trying to gently rock/twist the trans. DO NOT LAY UNDER THE TRANS WHILE DOING THIS AS IT MAY COME APART VIOLENTLY!!!!!!!!!!!!!!!

 

After doing a lot of research (forums and other searches) I have a feeling that the input shaft is seized in the clutch plate. I am going to spray some PB blaster up in it and keep the back pressure of the come-along. Hopefully after a full day of that pb blaster working, it will break loose. I will keep everyone updated and thanks again for all the help!

 

there are 2 bolts the hold the dust shield to the bell-housing did u remove them????

 

Yes, the bolts on the dust plate have been removed. I was not able to do any work to the truck this past weekend due to the rain in VA we got....I will update everyone as soon as work resumes.

 

I had the same issue with my brother's Mazda 5 speed equipped ford truck and the funny
internal slave cylinder assy. I wrapped the come along to the differential, hokked one of the reinforcement ribs on the tranny and while supporting it with a trans jack, I ratcheted the come along with slow but good results. Just make sure that the trans isn't sagging, creating angular deflection on the input shaft etc.

 

Capone, we did exactly that and "POP" the trans and engine separated....let the install begin. Thanks for all the help guys!

 

make sure you put a new pilot bearing in there and throw some lube/grease on the throwout bearing.

 

RUJusten "Capone, we did exactly that and "POP" the trans and engine separated....let the install begin. Thanks for all the help guys!"
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NICE!!! I deserve a beer.....it'll have to wait till easter though.



Glad i can help!!!

Kem also posted something very important as well.