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lugnut 02-14-2001 04:00 PM

Pilot bushing too small!! Now what?
I replaced the pilot bushing in my jeep, and now the clutch alignment tool wont fit! The bushing fit fine over the input shaft of my t18, but now that it's installed I don't think it will. I measured the id on the bushing and it was .665, and the input shaft measures .666. This is on a '77 cj5, with a t18 out of a '77 cj7. My old pilot bushing had a ton of slop in it when I slid it over the input shaft. What gives?

Lugnut 77 cj5

Pigpen 02-14-2001 04:20 PM

Re: Pilot bushing too small!! Now what?
Is it possible that the bushing compressed during installation. Are you sure you didn't (I don't know the appropriate word) fatten the bushing by wacking it during installation. It probally just flared a bit on the wacking edge. I would install another to be safe or just knock the allignment tool into it to stretch it out.

76 CJ5 360/T18A/Bronco gear D20/D30 big brake disc, locker/D44 big drum working on disc/ factory slip/4inch lift/33's/6000lb winch/All Fiberglass/electric fan/full cage/ appetite for MUD

CJDave 02-14-2001 04:22 PM

Re: Pilot bushing too small!! Now what?
[img]/wwwthreads_images/icons/tongue.gif[/img] That's pretty unusual, but it COULD be slightly deformed from installation. Also....check the O.D. on that clutch tool. They are sometimes not very precise. If you need more clearance you can ream the bushing to size or use a rolled up piece of emery cloth in a rod and spin it with the drill. You can also use an old tranny input shaft to wallow out the bushing and get it back to size and shape.[img]/wwwthreads_images/icons/crazy.gif[/img]

Quadra-Tracs modified While-U-Wait by the crack moonguy[img]/wwwthreads_images/icons/wink.gif[/img] Quadra-Trac Team.[img]/wwwthreads_images/icons/tongue.gif[/img][img]/wwwthreads_images/icons/smile.gif[/img]

ozarkjeep 02-14-2001 05:11 PM

Re: Pilot bushing too small!! Now what?
if the trannys input shaft will fit inside the bushing now that its installed, but the alihgnment tool wont, then I would work on teh ailaignment tool and not the bushing.

its hard to think .001 will keep the tool out of it?

Id bet you kicked up a burr or knick on it and thats holding you up


"If thats the way that you want it, well thats the way I want it more..."

Reitman 02-15-2001 02:53 AM

Re: Pilot bushing too small!! Now what?
As my friend the mechanic put it after my tranny wouldn't go back in..."You were a little too agressive when you hammer that sucker in."

Who ME?????
I used a mallot to hammer it in, but I guess I just hit it too hard. We had to use a little grinder to make it fit. The bushing fit fine over the input shaft and alignment tool origonaly, so I know it got mis-shapen at some point during the install.

What did you use to put it in with?

Just try like Dave said and grind it out a bit.


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