Installing the 2TG

After letting the paint sit and harden for 3 days I finally decided it was time to start reinstalling all the parts removed from the engine bay prior to the paint project. first things first I decided to install the New Clutch Master Cylinder and newly replaced  Brake Master cylinder. The clutch Master did not fit properly due to the firewall configuration so I had to notch one edge with the grinder to make it fit properly. At the same time I installed the proportioning valve for the rear brakes and all the other hydraulic lines.

Saturday 03-27-2004

Bright and early(10:00AM, LOL) I am in the garage to get to business and get as much done before it is time to come back in and enjoy Baby Duties for the evening. I have a hell of allot of work to get done in a little time. I was getting bored trying to get a good plan of attack so I decided to install the engine and Gearbox first. The only issue with this was the simple fact I could not remove or install the gearshifter from inside the drivers cabin unless I wanted to tear up the carpet and remove the riveted cover. To hell with that I have already ripped enough of this car apart! so the plan is have gearbox waiting under the car to be mated up with the 2TG that I will drop in from the engine bay. A Pain in the ASS I knew is was not going to be easy, especially since this is a One Man Project....ME!

Since their were many other things I could have done while I was painting, I didn't do them! I needed to install the New AASCO Motrsports Flywheel and Clutchnet Pressure Plate and sprung 6 puck disc so now is a good time to do so! After a quick run to the hardware store to buy some Loc-tite it was time to find the repair manual for the torque settings of the bolts on the flywheel and for the pressure plate.

Old vs. New

The weight difference is SO MUCH! I didn't have a chance to weigh the whole setup but I think the Flywheel, pressure plate, and disc are about equal to the weight of the the old flywheel or really close!

Damn I forget the clutch alignment tool! one of these days I will remember some of the cheapest tools are the most important! So after I found the repair manual and had Loc-Tite in hand it was time to install flywheel and the 6 bolts torqued them down to 50LBS even tho the facory recommended 42 max, OH well! the pressure plate bolts were also Loc-Tite'd and torqued to 20LBS compared to the factory suggested 14LBS!

Now it's time to get the motor above the chassis without scratching my paint and drop it under the car to line the gearbox up. this was easier said then done! the HUGE oil filter was in the way of the sweetspot to get the motor between the the radiators supports. So I chose to go over and the down!

Once I managed to get up and over the chassis it was time to drop the engine CAREFULLY down so I can line up the gearbox. this turned out to be a small headache but was easier than I anticipated! I used a old U-Haul Blanket to keep the front crossmember and radiators supprts form getting beat up. I only made contact once with the motor and X-member but that was just because I lost my balance because I tripped over the air hose!

The motor is lowered, HOORAY! now for the hard part lining up the gearbox and the 2TG. Things didn't go all that bad. My eyeballing of the disc was spot on and didn't need the alignment tool. the tricky part was having enough room to wiggle the gearbox and not break the shifter that was getting it's beating in the transmission tunnel every time I rocked the gearbox back and forth. after about 45 minutes I had the motor and gearbox mated perfectly. I looked for another 15 minutes to find most of all the bolts and the Starter. Note: I though the cheap ass $20.00 jack I bought a couple of years ago was just taking up space but it has found a use Today. I could not get either my race jack or normal shop jack under the car far enough to lift up the tail of the gearbox. I guess being a Pack-Rat sometimes pays off. BTW you want to buy some 3TC parts :)

Once all the above was done it is time for a long smoke brake! I contemplated cracking open A corona or Fat Tire but the last thing I need is some Alcohol to make fuzzy what little brain cells I have left after all the paint fumes! After the bit of R&R was done I needed to lift the gearbox up and bolt up the X-member for the gearbox. that was a piece of cake. Mounting the Motor to nothing was spectacular! I had to get the front X-member in and bolt that up so I can get the engine mounts

Once the X-member was installed I mounted up the Exhaust Header. I had to remove the Thermostat housing and the outlet housing to  squeeze the header in but it BARELY FIT!!

03-28-2004

Today I didn't do much. pulled the oil pan to find two quarts of sludge in the sump. cleaned pan and oil pump, reinstalled pan with new gasket and started to bolt up all the front suspension. all I have left before dropping car back on the ground is bolt header to exhaust, install steering arm link to steering box and tighten the drivers side swaybar link. 

I have busted my ass so I will take a brake until Tuesday night or Wednesday night. then I can start to focus on getting the intake side of the motor installed and then on to the EFI!

04-03-2004

Only had a chance to work on car for a few hours. The good news is the car is finally on the ground after 4 months. Intake Manifold and throttle bodies are temporarily installed. fuel delivery system is currently being adapted, the only downfall so far is that I am on a budget and really want to use braided lines and compression fittings along with a surge tank but I have to settle with the braided hose I have laying around and use hose clamps and pray that I can turn a corner with less than a half of a tank of gas :). Tomorrow I will finish up fuel system and pressure check and make sure all is good before I move on to the cooling system and heater. Then it's time for the wiring! I am leaving the front body panels off until I close to finished with the wiring. 

MORE TO COME SOON!!