Hi Guys i really need your help asap, i took my 1600 pinto out of my kit car today and i am putting my 2ltr pinto in that i have been working on for weeks, i thought id got it all sorted but i can get the engine to fit tight to the gearbox, i think i need to take the clutch back of and line up the teath am i right or am i missing something. the spline fits in but it just wont fit tight and i dont wont to force it. im using the clutch from the 1600 is this a problem. im using a 5 speed type 9 box. any help would be great, and advice on twin webbers as thats my next job.

Are you using the same flywheel? May be fouling on the bellhousing or more likely like you say clutch alignment try rotating the prop as you line up

Hi Daz,

I take it you are using the flywhhel and clutch from the 1600 on your 2.0.
If this is the case it will fit straight onto your type9 box.
Just make sure that the friction plate is correctly lined up with the spigot bearing
or it wont fit together easily.

Also make sure that the clutch release arm is fully retracted and the
release bearing is clipped on properly.

Andy

Weigh it in for scrap then use the cash to buy a zetec and a holiday for 6 in Barbados....

^^^^^^^^

tut tut.

Andy

thanks for your help guys, im going to have another go tomoz. coozer not an overly helpfull coment but if you want to pay for me and my mates to go on holiday i will deff give you me pinto engine. i bought a zetec to put in it but got put off because of the wiring, so i sold it and got a 2ltr pinto. i think i have lined the clutch up wrong i wanted to be sure the 1600 clutch and flywheel would fit 2ltr. thanks for the good comments.

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Originally posted by big daz2
thanks for your help guys, im going to have another go tomoz. coozer not an overly helpfull coment but if you want to pay for me and my mates to go on holiday i will deff give you me pinto engine. i bought a zetec to put in it but got put off because of the wiring, so i sold it and got a 2ltr pinto. i think i have lined the clutch up wrong i wanted to be sure the 1600 clutch and flywheel would fit 2ltr. thanks for the good comments.

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I agree with Coozer.

Zetecs are are doddle to wire up

Andy

When you have the engine and box split, take off the clutch and slide the plate over the gearbox input shaft to test that it slides on.
Usually it's just a misaligned plate, a lift smear of grease or some WD40 helps, often you can get the box part on then use longer bolts to pull on the box, make sure the box is dead level to the engine.

Sounds like you need to centre the the clutch driven plate properly ---- this needs the use of a special tool ---- Clarke CHT426 Clutch Alignment Tool


Also did you check the driven plate was the correct number of splines for the gearbox, although this dosen't apply to the 5 speed gearbox if the car has a 4 speed gearbox various types can be fitted.

mate engine and gearbox outside the chassis and then lower in!

Some 1600 boxes have less splines as i found out the hard way. you may have to use a 1600 clucth and plate

thanks guys turns out your right i didnt have the centre aligned properly i took it all apart put back together and went on a treat.

coozer i was put off the zetec from all i had read up about it. the engine cost £60 but the rest of everything i needed would have cost alot over my budget. as it turns out i have only spent £200 on engine and twin dellortos and manifold and all the bits.

thank for all the help guys

right guys all in and tuned ready to go but, when i put her into first gear she doesnt want to drive untill the clutch is vurtuly right up, its the same in first and reverse obviosly havent tried any other gears. is that i have grease marks on the clutch and flywheel and this will go or do you think i have done something wrong. all good otherwise and clutch and gearbox was perfect before hand. Help

It sounds the same as the problem i had, had to use the 1.6 clutch plate fly wheel etc on the 2.0 block

thats what i have used. its the clutch i had on the 1600, its a 5 speed type 9 box. it does drive but the clutch fells as if its still ingaged a bit so im not getting the best out of the new engine.

do you have a bit of slackness in your clutch cable? if not, slacken it off a bit.
also, is the release arm not up against the bellhousing?if it is, either the clutch is worn out or there is something amiss with the release bearing.
it is doubtful that grease contamination will burn off, it usually causes judder at best, was the flywheel rusty when you fitted it, if so, it will have cleaned its self up and now requires adjusting.
hope this helps.
p.s. regarding engine, i'm with coozer.

thank you mate, iv just been out in her and i can engage gears but i cant get her into first while the engine is running but if i turn her off then i can get her into first and i put the clutch in as far as i can she will start but i can feel the car slightly pull so the clutch isnt fully in. there is a slight bit of slack in the cable. im with coozer also but imo it was more work to fit the zetec unfortunatly im not made of money and the kit car is a bit of fun and i didnt want to spent over a grand on it i got rid of my impreza type r because it cost too much money so i dont want this costing me to. thanks for you help.