I had the same problem once. It ended that the new Nissan clutch disk had some rough spots on the splines that needed filing. It sucked because I had to take the whole thing apart.

It was 1/2 inch back like you describe.

Has anyone really been dumb enough to try & start the motor while in my predicament? I sure hope not. The transmission's in neutral & I've spun the shaft, but NOT while I was trying to put it in the motor. I don't think anything's "razzed" up because I've taken it in & out before w/o a problem, albeit with some assistance, that's why I've got to get someone over here to help. It's still on two jacks (Front & Rear) & has a strap assisting with the rear through the shifter hole.

After thinking about it longer, I'm wondering if either sblake's right that I need to "hit the right angle/pitch" because it's tough while on your back & no room to maneuver around. It's a cheap aftermarket clutch, which also makes me look into GreenZZZ's problem, but I got it on the back side of the block fairly easy.

Plus you we're able to fit the alignment tool through it.

My alignment tool fit fine, but my transmission splines didn't. After I ripped it apart I tested the clutch disk on the transmission spindle and it wouldn't go on. After filing it (and vacuuming the dust off) I put the thing in straight away. I only had to file the leading edge, not the whole length of the spline...

Transmission angle alignment is also tricky...

The transmission's in neutral & I've spun the shaft...

Spinning it in neutral does nothing. It must be in gear so that spinning the mainshaft also spins the input shaft, which is the part that needs to be spun.

My alignment tool fit fine, but my transmission splines didn't.

My alignment tool is an old main drive gear from a 510 4 speed, not the plastic one that most people use.

FYI - if you converted from an automatic transmission.. you need to remove the backing plate from behind the flywheel.

if not.. the transmission just needs to be aligned properly and some patience =)

Well I pulled the engine out again tonight. I think the splines on the clutch are the problem. I took some pictures but they weren't clear enough to see.

First, the transmission splines are ok, I checked them thoroughly. But the clutch splines aren't sharp in spots, & look like they've been flattened a little in those spots. That's the best I can describe it.

I'm willing to guess that it happened because I was trying to install the thing on the wrong angle & I probably did the damage the first time trying. I guess I'm going to order a new new one tomorrow.

Just one more thing, I don't remember specifically, but now the clutch alignment tool doesn't go all of the way into the clutch, only about a half inch. Shouldn't the tool go further into the clutch than that?

Edit: And Prox, it's a manual all the way.

I'm going to try & post a couple of pictures to try & show what I'm talking about. I'm no photographer so bear with me. Look on the rounding of the splines on the bottom of the clutch. I think that's where I was doing the rubbing trying to get it on while it was at the wrong angle.

The clutch plate alignment tool should go all the way through the plate and seat into the thrust bearing. In my mind.... that last bit where the alignment tool seats into the thrust bearingmakes the tool straight.... The fat lady sings

Jay

zdisease

PS The idea of having a pilot shaft (input shaft) as a alignment tool is the best idea.

RC7, looling at your second picture, it's obvious that the clutch disc is not aligned and you'll never get the trans in with it in that position. Loosen up your pressure plate and follow Jay's advice ^ making sure the alignment tool is firmly seated in the pilot bushing before you re-tighten the bolts.

Your splines look better than mine did. Like Stephen and Jay mentioned, the clutch tool needs to seat all the way into the pilot bearing in the crank shaft which puts the disc perfectly in the center of the pressure plate.

Loosen up the pressure plate, jam the tool in all the way and re-tighten the plate. Might want to pull the whole pressure plate off and test fit the disk on the transmission splines and file if necessary, but it looks okay from what I'm seeing...