Description: Attaching the clutch disc and pressure plate to the flywheel/engine.
Tools Needed: Wrenches, the two old bolts that connected the gas engine and transmission, starter block-off (from kit), Chain?
Estimated Time: 1 - 3 hours.
Purpose of this step: This is the fully connected engine/flywheel/clutch/transmission, similar to what was pulled out of the car. This all goes in in one piece, then will be mounted where the old engine/tranny was mounted under the car (Next Step).
I had the engine/flywheel/clutch assembly on one furniture cart and the tranny on the other. The ridged opening hole in the clutch has to match up in height with the shaft in the transmission and as you can see in the picture, I was off by a couple of inches. Figured that if the engine sat on some 2 by 4's on the cart, it would just about make up the difference. Also take note of the hole on the right side of the transmission where the starter used to be. That will be covered by a "starter blockoff" from the kit, since an electric starter is unnecessary with an electric engine.
This was pretty close (balanced out with some cardboard under the tranny and I tried to slide the clutch spline onto the transmission shaft. I had a lot of problems getting this on. The shaft from the transmission would only go in part way. I spent a long time trying to get this on and finally took a break, at which point my neighbor happened to come by and told me some things about the Island of Malta, that intrigued me and I made a mental note about looking at it for a possible vacation destination in the future. Then I had some lunch. By that time, I was feeling pretty good, so I headed back out to try again. I also sprayed a little WD40 on the transmission shaft. Then I tried to connect the two again and:
Either that break reinvigorated my determination or the WD40 did the trick. I'll never know for sure. Anyway,there are 4 bolts for the attachment. The two top bolts are the ones used to hold the gas engine to the tranny and two new ones supplied in the kit. Note also the starter block-off attached and covering the hole where the starter used to sit. There really isn't much else to it. Now, the manual suggests that you first bolt on a chain to use to lift the transmission up onto its connections under the car, then take that off and rebolt. I am going to try to hook it up without doing that. I think that the two furniture carts should help me set everything up. I am still waiting for the mount that was supposedly sent out by ElectroAutomotive, so I'll let you know how it went without the chain once I get the chance to try and hook it up.
After finishing, I headed out to a ranch in beautiful Cayucos (the last of the surf towns 30 miles south of the Big Sur coast), to see Elizabeth Kucinich speak about her husband's run for president, impeachment and other subjects. She is an eloquent speaker (a Brit) and a beautiful woman. I hope her husband is successful with his current proposal in Congress.