Ford 4610, refitting engine on gearbox - 2mm missing..

Hi Guys.

So it was time to refit the renovated engine to the gearbox.
It went smoothe until the last 2mm.

The splines seems to lock in, while still gapping 2mm there is no problem turning the engine by wrenching the crankshaft. But when I tighten the engine the last 2mm on to the gearbox, I'm unable to turn over the engine.
The gearbox is in neutral while trying this..

After adjusting the clutch lever, the clutch feels normal, but enganging the clutch dosent solve the problem.

I have tried to taking it apart and try again, same resault.

I have fittet a new clutch plate if that makes any difference..

Any thoughts?

These are just wild a$$ guesses...
clutch plate too thick, making pressure plate bind on the housing?? Pressure plate installed wrong and missed dowl pin? Clutch plate installed flipped over and pushing pressure plate too far back?

Is it the same pressure plate or a new one?

(quoted from post at 16:07:00 07/01/18)

These are just wild a$$ guesses...
clutch plate too thick, making pressure plate bind on the housing??

Click to expand...

I dont think so, I should see paint markings on the clutch pressureplate, I think.

Pressure plate installed wrong and missed dowl pin?

Click to expand...

No, checked that

Clutch plate installed flipped over and pushing pressure plate too far back?

Click to expand...

All the images says to install the clutch plate with the "tip" towards the gearbox, isent that right?

Is it the same pressure plate or a new one?

Click to expand...

Same pressureplate..

Thanks for your suggestions

Got the 1/8? steel rear plate bolted to the block?

Your clutch disc is backwards. Good thing you didn't suck it up with the bolts, otherwise really bad things would have happened. Don't ask me
how I know that!

(quoted from post at 17:36:38 07/01/18) Your clutch disc is backwards. Good thing you didn't suck it up with the bolts, otherwise really bad things would have happened. Don't ask me
how I know that!

Click to expand...

You are right, the old clutch plate had a "flywheel side" sign on it, and the new one didn't, so I installed it after the drawings.
I have flipped the disc, and it went in after a little wiggeling

What damage did you cause Bren? Just out of interest..

Many moons ago, back when I was young and dumb (early 20s), I put a clutch in a 4600. I was in a hurry, and installed the disc like I've
always done - hub towards the back. When I went to put it back together, I had the same issue that you did, except that I ended up sucking
it together with the bolts. I was in a hurry because I was irritated - I had to work late until it was done.

When I got it all back together, I went to start the engine and it cranked very slowly, but not fast enough to start. I got a jumper
battery, and it cranked a little faster, but still not fast enough to start. I then got the booster, and it finally fired off, but
immediately I could hear the engine laboring. By the time I realized something was amiss, smoke started pouring out of the breather tube. I
quickly shut it off, but the damage was done - I smoked the thrust bearing. It ended up ruining the thrust surface of the crankshaft as
well. I ended up taking the engine out, putting it in a stand, flipping it upside down, and replacing only the crank and bearings - I left
the head on and the pistons undisturbed.

To add insult to injury, not only was the clutch disc warped beyond repair, I also blew out the snap ring in the transmission bearing
retainer. It also broke the retainer itself. Needless to say, by the time all was said and done, it was a very expensive, and time-
consuming, screw up.

On the bright side, it taught me to be more cautious, and to never let personal irritation or lack of time get in the way of doing quality
work. I tell this story to my students every time we cover clutches. Hopefully no-one makes the same mistake I did.

Good story I think we have all been in that situation, you just paid a big price :/

Bern, thank you for the object lesson. I know how it feels when ya do something like that.