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Old 11-29-2011, 01:58 AM   #1
Scooby Newbie
Member#: 301113
Join Date: Nov 2011
Angry Installed engine- now clutch will not engage...

Looked around but not finding any straight answers from Google on this one...

I just had my heads re-worked, and when I put my engine back in I cannot get the clutch to engage. It is a cable clutch, and no amount of adjusting seems to work. When I tighten it up you have to really press it hard to the floor to get the engine to start (clutch has to be in to start), but it is not tight enough. When you start it in gear there is a difference in the amount it is engaging while driving in first, but its so bad you can't even shift to 2nd. I had to stop the car to even get into reverse.

Everything was OK before the engine was pulled, any thoughts? I had a heck of a time getting the engine in, would that have anything to do with it?
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Old 11-29-2011, 07:45 AM   #2
Patrick Olsen
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Member#: 120
Join Date: Jul 1999
Chapter/Region: AKIC
Location: Where the Navy sends me...
1997 Legacy 2.5GT
1996 Impreza coupe


It certainly sounds like something didn't go back together right when you stabbed the tranny into the engine. If I were you I would separate the engine and tranny again, give everything a thorough once-over, and then put it back together. If everything is lined up right, the engine should mate to the transmission almost effortlessly. I know I had a helluva time getting them to line up and mate up the first time I did a swap, but once I got it right, they slid right together.

Pat Olsen
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Old 11-29-2011, 03:50 PM   #3
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Join Date: Nov 2011

Well I found out if I loosen my mount bolts the engine starts to slide away fairly easy. With the bolts loose the clutch works fine. Gently tighten the bolts around the starter- still good. Gently tighten a bolt on the passenger side- nothing. Clutch won't engage. When there is about a 1mm gap on the passenger side between the engine and tranny the clutch works perfectly, close that gap an no good no more.

Bent input shaft? Does anyone know how to take those out? Do I need to pull the transmission for that? (shudders)

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Old 11-29-2011, 06:53 PM   #4
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Join Date: Oct 2010

Sounds like possibly a pilot bushing. Try having someone else press the clutch while you tighten that passenger side bolt. If everything is not perfectly lined up you can get the input shaft through the clutch and almost into the pilot bushing and the it starts to bind. If you press the clutch while pushing into place, everything slides right in. It's easy to try.
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Old 11-29-2011, 07:00 PM   #5
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Join Date: Jul 2007
Chapter/Region: BAIC
Location: San Ramon
1996 Turbo Outback
9psi on 91 No EM


Seperate then try again. It should not need to be forced when lined up. The input shaft is one of those things that you put some grease on it, then you wipe the grease off. This will help you get it in as well.
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Old 11-29-2011, 07:15 PM   #6
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Took it back out and tried again. Everything went a lot better this time. Practice sure helps. Placing a small 2x4 under the tranny makes things a lot easier, as does removing the rubber connector to the back fiewall.

Anyways, I took everything off, inspected, and put it back on. Not sure what is different this time, but it works. Pretty good, as a matter of fact.

No idea what is different, but I will take it. Thanks for your help guys!

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