Rav 4 Problem

[wa5]

Had a bloke talking to me today about his 96 Rav4

He had rebuilt the original engine, and had the fly wheel machined, and fitted a new clutch kit.

when he tried to fir the engine, the pressure plate hit the inside of the bellhousing.

He put the original clutch / pressure plat back on and tried again... same result..

he is stuck..... anybody ever had anything like this?

[thechuckster]

is he sure someone hasn't attached or left a spacer onto the crankshaft (where the flywheel bolts up)?

Or damage to the centre-bore/crankshaft flange preventing the flywheel from seating onto the crankshaft?

Or did he get the right flywheel back from the workshop that machined it?

[wa5]

He came in to compare the flywheel I had, with his, they were the same....

Something stopping the flywheel from seating correctly would be my best bet.

[Rens]

Is he putting it on backwards?

[wa5]

Dont think the pressure plate would bolt on...

Only other thing I can think of, is that the whole crank is sitting "wrong" IE the cranck thrust bearing is somehow wrong and the crank is sitting back too far? if such a thing is even possible

[thechuckster]

very, very much doubt it - rods would be smashing against the side of the journals and making awful sounds if the thrust bearing had failed.

More likely it's an assembly thing - has the guy put the clutch disk on the right way?

[pandaah]

Is he sure the pressure plate is hitting the bellhousing or he just can't line the input shaft up in the clutch properly and saying thats his problem, never heard of that in my life, and if he used the original bits and it still won't fit then its definetly something hes doing wrong, how far can he get the gearbox over the clutch?

[Rhyno]

I wonder if he used a clutch aligning tool or the mach 1 eye ball....