JosueP5's '03 Protege5 Build Thread.

Hmm, interesting on the motor mount. I'll still take/pay for that pass side insert and possibly the drivers side depending on what it is.

The clutch alignment tool is for the V6 but it might work. I think I still have Levi's alignment tool for his 2.3 as well. Who knows, they might still fit.

And try this link for the manual. If it doesn't work I'll just bring my lap top and you can save it to your computer. No worries.
 
Half inch extension works as a clutch alignment tool... so I've been told...
 
I don't know, I'd rather do it legit. It'd be bad news to have that thing be in there wrong. Though, we'd just have to keep fighting the tranny to get it to line up. Hopefully Evan can dig one up and it fits...nobody rents these out. Short of me buying a new clutch kit, using the tool, and returning the kit the next day, I don't know how I'm going to do this...lol


Just got in from doing the timing belt, pulleys, water pump, and I switched out all the accessory type stuff from nasty OH to clean TN. hehe Just ran to Auto Zone and picked everything up. Could've been cheaper through Rock Auto, but I didn't want to wait any longer.

Timing belt straight up mauled me...the crank and cam gears got out of whack. Took me over 2 hours to finally get it all lined up. FAWK!!! My fingers are chewed up soo bad right now, s***'s kind of sharp! I feel like I've been sanding with 36 grit paper! It's on there though, and seems to be right. I cranked it over a few times and everything lined up again.

I bought a front crank seal kit, and cam seals, but I bitched out on putting them in. I wasn't sure if I had to remove that little cover the crank seal is in, or if I just get a pick tool and try to rip the old seal out?? In any case, the seal in there looked pretty good still. And I just didn't feel like removing the cams and all that hoopla. I'll cross that bridge if/when I get there...screw it.
 
Yikes...that sux dude and has me second guessing doing mine. If I should opt to tackle it, I'll be going to my bro-in-laws. He has a few more tools than I plus a compressor and air tools. :)
 
Yea, definitely would've been a total nightmare had that happened while in the car. I was shitting bricks when this was happening as it was! All these doomsday scenarios started going through my head. Like, what would happen if I couldn't get it squared away?
 
I hear ya, I have those scenarios run thru my head when I think about doing it. haha Guess you didn't put that rubber wine cork between the gears prior to removing the belt? I'm not a wine drinker but I'll buy a bottle simply for the cork as it seems to have worked well for others.
 
I tried the method I saw in a how on here, 2 wrenches zip tied together, but it still allowed the gears to move...fail.
 
the trick is to set one of the cams retarded because you know its going to advance that way it will slip into place. easier said than done but it helps.

also a little late on this, but i dont take the wheels or anything off when removing the motor and tranny together. i just unbolt the half shaft and leave it attached to the axle and i start lifting th motor slowly while going down to knock the axles out and just jack up the engine slowly while pulling out the axles. installation is a little more difficult and you will need one person on the hoist and one under the car and sliding the axles in as the engine is lowered into the car.
 
I don't know, I'd rather do it legit. It'd be bad news to have that thing be in there wrong. Though, we'd just have to keep fighting the tranny to get it to line up. Hopefully Evan can dig one up and it fits...nobody rents these out. Short of me buying a new clutch kit, using the tool, and returning the kit the next day, I don't know how I'm going to do this...lol


Just got in from doing the timing belt, pulleys, water pump, and I switched out all the accessory type stuff from nasty OH to clean TN. hehe Just ran to Auto Zone and picked everything up. Could've been cheaper through Rock Auto, but I didn't want to wait any longer.

Timing belt straight up mauled me...the crank and cam gears got out of whack. Took me over 2 hours to finally get it all lined up. FAWK!!! My fingers are chewed up soo bad right now, s***'s kind of sharp! I feel like I've been sanding with 36 grit paper! It's on there though, and seems to be right. I cranked it over a few times and everything lined up again.

I bought a front crank seal kit, and cam seals, but I bitched out on putting them in. I wasn't sure if I had to remove that little cover the crank seal is in, or if I just get a pick tool and try to rip the old seal out?? In any case, the seal in there looked pretty good still. And I just didn't feel like removing the cams and all that hoopla. I'll cross that bridge if/when I get there...screw it.

I was saying that because that's what my dad did when he swapped the 5 speed into my Miata. If something wasn't right with that install, the 6 puck, unsprung clutch would have let me know (by coming thru the bellhousing) a long time ago. Just because there is a fancy, single purpose tool out there doesn't mean that it's the only way to do something...

And in the ACT box in the garage is an alignment tool for the Miata. Not sure if the input shaft size is the same. I'll try to dig it out before I leave.
 
That's reassuring! I've just never done this before, and I have certain conceptions (some mis-conceptions lol) about some of this stuff, using a clutch alingment tool to get the clutch in there perfectly was one of them.

I want it to go as smoothly as possible, and so far, NOTHING has! Took us 45 minutes to get a tranny off, couldn't fully bolt the block to the stand because we didn't have long enough bolts so I had to work around the picker all last night, snapped an intake manifold bolt off in the head, took me longer to do the timing belt with the engine on a stand than it takes for some people to do it in the car, and who knows what's in store for the rest of this build! Ah well....that's wrenching I guess.

I have a bunch of parts to ship out after work, then I'm meeting up with someone local to do a trade+cash swap for my radio, then I need to tackle the ECU wiring and get that out of the way. Tomorrow I'm hoping to drop the motor in!
 
The plot thickens... Stay tuned, more high drama in the next episode. Relax Josh if you get into a serious bind there are enough guys close to you that will be more than willing to help. Except maybe Evan, he has his own drama in "his side of the garage". I just wish I were closer, I would love to help both of you out. A smidge over an hour to get there makes it tough to do.
 
I want it to go as smoothly as possible, and so far, NOTHING has! Took us 45 minutes to get a tranny off

Hah! It probably took me a day to get my tranny off, in fact I think I tried one day, gave up and did it the next day :P

You're rushing too much, slow down and enjoy the work!
 
What Cheese said Josh...slow down and take some time. You have the luxury of having another car to drive for the time being. Where as I will be the one rushing around like an idiot as she's my DD and can't afford to have her down for more than a long weekend. :)
 
You guys are silly! How am I rushing this? I'm not running around like a NASCAR pit crew as fast as I can. I grab my tools, and start to work on the car. How am I supposed to do it....pull a bolt out, have a seat and analyze my next move.....pull another bolt out....look at the manual....unplug something...color code where it went and take a picture just in case...check the forums for anyone else who may have gotten a picture...remove the part...inspect it for 30 minutes for no reason at all...oh wow, it's 11pm, guess I'll pick this back up tomorrow after work.

And having a car with no A/C and a non operational driver side window when it's in the 70's, that also gives you back pain from a worn out driver seat is HARDLY a luxory. lmao

The car will get done when it gets done, and naturally I want that to be sooner than later, but I'm by no means rushing or cutting corners to make that happen. I'm working on it when I can, and trying to get all the parts lined up so I can start driving it ASAP instead of finding out I need something, and having that delay it's maiden voyage a few days. Then I need something else, so more days...vicious cycle! As far as the tyranny goes, I thought you just unbolted it from the motor and it slides right out, another misconception since I had never pulled a tranny. Essentially it does, but it took us so long because we had to figure out which bolts to take out, then took a while to wiggle the input shaft out.
 
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How am I supposed to do it....pull a bolt out, have a seat and analyze my next move.....pull another bolt out....look at the manual....unplug something...color code where it went and take a picture just in case...check the forums for anyone else who may have gotten a picture...remove the part...inspect it for 30 minutes for no reason at all...oh wow, it's 11pm, guess I'll pick this back up tomorrow after work.

Have you been watching me work? lol

It just sounds like you're rushing, but if that's not the case forget what I said.
 
Like Cheese said it sounded like you are rushing with some of your posts. And I fully understand about wanting to make sure you have all of those little parts in hand so you are not delayed further waiting for a bolt or two. Carry on as you have been and hope you'll get to turn that key sooner than later.
 
No worries! Everyone's wrenching methods are different.

I went ahead and put insurance on it in anticipation of a few test runs around the block this weekend. Need to get a temp tag still.
 
Relax Josh if you get into a serious bind there are enough guys close to you that will be more than willing to help. Except maybe Evan.

Hey. I'm coming over this weekend to help. So there, Larry. Haha
 

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