New Academy Kit - Attaching gearbox to engine?

[Migraine]

Morning all,

I have a potentially daft question here, but I thought I'd ask the masses out there rather than damage my new car ..

Last night I tried to mate the gearbox + bellhousing to the engine (sigma 125). The problem is I just can't get the damn thing to go in. I think the shafts etc line up, ut I am unsure how much force is needed to get them in far enough. Some gentle persuasion with a soft hammer didn't do the trick.

Right now everything is still out of the car, and I have an engine hoist.

Any pointers?

[Sam_68]

Are you sure the clutch plate is properly centred?

[Migraine]

I have to assume so, it came pre-assembled on the engine.

I'll take a look when I pop to the garage later today.

[Sam_68]

If you haven't checked, that would be my first thought... if the clutch plate is not centred, it'll never go together.

Other than that, it might take a bit of rocking and wiggling to get the engine and gearbox to basically engage and line up well enough to get the bolts in, but you might then find that you need to use the bolts themselves to finally tighten everything up.

[GreenV8S]

While you're fighting with it make sure you don't damage the splines.

[BertBert]

do you have access to a clutch alignement tool input shaft spline thingy?
That would help. There's one in my garage in EPsom if it is of any use.
Bert

[Migraine]

Thanks for the tips guys.

I managed to get it all together last night, by using various bolts to pull the two together. It was quite a tight fit, but I don't think anything was damaged.

[Migraine]

BertBert said:

do you have access to a clutch alignement tool input shaft spline thingy?
That would help. There's one in my garage in EPsom if it is of any use.
Bert

That sounds like the miracle wonder tool I was swearing and cursing for last night! For future reference, what is it?

[Sam_68]

Migraine said:

For future reference, what is it?

It's a clutch alignment tool.

Basically, it holds the clutch plate dead central on the clutch cover as you bolt the clutch cover to the flywheel, ensuring that the gearbox input shaft will line up with the splined centre of the clutch plate when you assemble the engine and gearbox.

You can buy them from any decent motor factor and the cheap plastic ones (which are perfectly adequate if you only expect to use them once or twice) cost about £8.50.

One would like to think that Caterham centre the clutch plate for you when they assemble the engine for the kit, but I wouldn't want to guarantee it. If you ever change the clutch on a car they are pretty much an essential - you can assemble a clutch by eye, but it's a lot easier and more accurate with the correct tool.

[pouch]

Hi, A couple of the guys had problems with the splines on the GBOX last year which made it difficult to assemble, and then also meant that the Clutch would not disengage..
Caterham changed it on the post build check.

Where abouts are you in Berkshire?
I am in Oxford, let em know if you have any questions about the 2009 academy

You are in for some serious fun....

[Migraine]

pouch said:

Hi, A couple of the guys had problems with the splines on the GBOX last year which made it difficult to assemble, and then also meant that the Clutch would not disengage..
Caterham changed it on the post build check.

Where abouts are you in Berkshire?
I am in Oxford, let em know if you have any questions about the 2009 academy

You are in for some serious fun....

Eeep, consider me spooked!

When you say Caterham changed "it" on the post build check, what did they change?

[pouch]

They changed the gearbox, I understand it was because the splines were not machined far enough down to enable the clutch to disengage... at least I think that is what they said.

I'd be suprised if that is the problem as they should all be rectified by, I guess it was just a batch

[Migraine]

Well, here's hoping.

Currently having a few more problems, but I'll make a big "help!" post tonight once I make a proper list (wiring up the engine bay, and the manual is *useless* for explaining things properly).

[OJ]

If you're assembling with the gearbox in the car then try moving the car backwards and forwards a bit with it in gear to turn the splines round, it might be as simple as that.

Also, make sure that everythings at the right angle for engagement

From experience with K-Series engines they usually go in within the first 30 seconds or you spend ages tarting about trying to get them to mate properly!

[Wotsthisbitfor]

Hello Migraine, I'm a little behind you with 09 Academy car, it got delivered last week minus uprights, gearbox and de-dion tube which are coming next week. Gone as far as possible with front suspension and looking ahead, the cooling system components came without inner and outer cowls. I queried the shortage and was told that the cowls are not used on Academy models. There are no references to radiator fit without cowls, have you noticed this and do you have any ideas?

[deadlast]

Hi,

I had the same issue with the missing heater cowl on my recently finished Academy 09 car as the manual kept referencing the inner and outer cowl.

I called Caterham...again:

Turns out that the old manual is still being shipped - if you go to the Caterham site and download the latest one it doesn't mention a cowl, but four plastic clips that slot in to the side of the fan instead.

Do not over tighten these! I did and it pulled the little bolt through the head of the clip - major pain in the derrier followed...

Good luck

[Wotsthisbitfor]

Thanks Deadlast, that's helpful. Is there still one manual for all the variants on the Caterham site or did you access an Academy Car specific one?

[deadlast]

Nope - one manual for all Sigma still, this one is later than the one shipped to me 4 weeks ago:

http://www.caterham.co.uk/assets/html/technical/AS...

[Migraine]

Wotsthisbitfor said:

Hello Migraine, I'm a little behind you with 09 Academy car, it got delivered last week minus uprights, gearbox and de-dion tube which are coming next week. Gone as far as possible with front suspension and looking ahead, the cooling system components came without inner and outer cowls. I queried the shortage and was told that the cowls are not used on Academy models. There are no references to radiator fit without cowls, have you noticed this and do you have any ideas?

I was told the same thing, the radiator doesnt need any cowls etc.

With luck, I'll get onto the cooling this weekend, so I'll find out for sure then