fitting the gearbox and clutch release lever

[DavidHill]

After finishing my engine rebuild, the next step is to fit the gearbox.  I have used a clutch centring tool to make sure the clutch bearing is centred in the shaft, so first step done. HOWEVER it seems to be impossible to fit the clutch release lever whilst also at the same time attaching the gearbox and bell housing to the engine block.  Its clearly not impossible, so does anyone have any advice on how to fit the release lever and gearbox?

[DavidHill]

a further question on clutch fitting.  see attached pic of my clutch housing.  There are two pins that are on either side of the release bearing and are protruding through from the clutch. Each of these pins has a large hole in, which looks like a large split pin would fit in.  Should there be split pins on these two pins?? My TAV drawings show an earlier clutch plate, so are no help. The engine was without these split pins when I dismantled it, and the clutch was working very well...so I suspect there should be no split pins...but then why is there a hole on each one??

[Sliding Pillar]

Hi David, it's a very long time since I have done this and I'm sure Simon will give you a step by step guide, but in very basic terms you have to remove the vertical actuation rod whilst bringing the gearbox and engine together, then put it back in place afterwards. This will give you the necessary clearance to get the forks behind the clutch release bearing.
Ade.

[simonandjuliet]

I tend to fit the clutch/backplate and levers to the 'box and then fit the whole unit to the engine , fitting the bolts via the window underneath. If you turn the engine carefully with the bolts not fully fitted, you can turn the engine, fit the bolts and then fully tighten them as you keep rotating the engine.

If the engine blocks, back off and tighten a bit more

I usually remove/fit the engine and gearbox as a single unit because it's quick and easy, especially with an S1 engine. A little bit more difficult on S2 or Lusso where there is a double bulkhead, then it is easier to fit without the rocker cover on

[DavidHill]

thanks Simon and Ade, in the end I used Ade's method (see pics)...it worked well...you do have to be careful that the fork is out of the way, but still able to be wiggled into the correct position once the gearbox is fitted (via a screwdriver from the hole above).  I now have the gearbox on and have attached the radiator too.  Will try to fit the entire unit as one today!

[Sliding Pillar]

Good news!
A few points on putting the engine/gearbox in with the radiator attached. 1) It makes the whole thing very heavy
2) I have done it a few times and on some cars the radiator is a very tight fit through the grille aperture. Take a few measurements first just in case!!

[davidwheeler]

I have always fitted engine/gearbox as one unit and the radiator afterwards.