I finally figured out my problem

[Project88]

So years ago when I was a teenager I bought this blue bronco 2 from my parents rebuilt the engine to spec, plus 30 over bore and could never grab gears in it after 6 times pulling the transmission to figure it out and having no experience with manual transmissions and not being able to fix the starter grinding situation I parked it and left it outside after putting the distributor module relocator kit on it. Well I'm 28 now and been in the automotive mechanic industry for 10 years and watching a YouTube video from simonfordguy about his inline 6 bullnose it hit me what I did wrong I trusted a fastener company to get my bolts right on my pressure plate. You guys remember that the manual pressure plate comes with m8 x1.25 by 15mm long bolts right? Well when I was a teenager I couldn't get them off without stripping the threads and ended up replacing everything top to bottom bolts including went to match up one of the bolts at my local fastener company and they gave me bolts that looked right well I never questioned them but my pressure plate was always 5mm from touching the flywheel and was flush would torque to spec too so I assumed it was fine now the older me knows younger me was inexperienced and up until 3 weeks ago didn't realize pressure plates gotta be pressed flushed against the flywheel this was the problem all along the bolts I had gotten were 5mm too long so when running seemed like it was right, so 28 year old me is going to give it another try here soon in the spring time and see if the old girl has any love for me after sitting outside in the weather for the past 4 years. Wish me luck, I'm gonna need it. Also gonna swap the starter drive for an escort 1.9 drive and maybe just maybe have a fun relationship with my first truck again.

 

[bobbywalter]

bottoming is definitely an ass biter.

 

[Project88]

bottoming is definitely an ass biter.

what do you mean bottoming? Oh shit nevermind Im still stupid bottoming out of bolts yeah. It is. Sorry been a long day working on Chevrolets computer systems they're dumb asf

 

[gaz]

@Project88
Not to suggest throwing away good parts or wasting money but if you need to disassemble it, perhaps consider changing it to the 4.0l clutch and starter

Since it has sat for the past 10 or 12 years, out of prudence, it may be worth the expense of:
• changing the oil (built up condensation)
• preventively replacing the head, exhaust and intake gaskets. I have experienced them failing from sitting idle.

It is a small expense for mechanical dependability ..)

 

[Project88]

@Project88
Not to suggest throwing away good parts or wasting money but if you need to disassemble it, perhaps consider changing it to the 4.0l clutch and starter

Since it has sat for the past 10 or 12 years, out of prudence, it may be worth the expense of:
• changing the oil (built up condensation)
• preventively replacing the head, exhaust and intake gaskets. I have experienced them failing from sitting idle.

It is a small expense for mechanical dependability ..)

Actually from my last post on here it's only sat for about 4 years. Last time I worked on it was 2020 and that was pumping the hell out of the clutch bleeding it cause I thought it was that but yeah no bolts were too long. So I'm charging the battery up on it and seeing if it'll take since it had the old break in oil in it. And it had extra zinc for the new lifters and all I'm gonna check the oil and see if it's got moisture in it if not I think it'll be fine cause I'll have to change it after break in period anyway as for the 4.0 starter I already have grinding problems how would a 4.0 stop that? I have a 1.9 escort starter drive coming to swap out in my 2.9 aftermarket starter. What all would I have to swap for that or is it the same flywheel and ring gear just starter. I figured it would be cheaper to just take apart the starter since it's ground off anyway and just fix it since the plates straight and it's got a new bellhousing with two good bolts, my flywheel doesn't seem to be bad just where the starter engages too far past the flywheel. As per my skill as a mechanic I have no doubts I can put the starter drive into the 2.9 starter

 

[sgtsandman]

The 4.0 clutch is a bit bigger and heavier built. It won't fix your issue with the fly wheel bolts or starter engaement.

 

[Project88]

The 4.0 clutch is a bit bigger and heavier built. It won't fix your issue with the fly wheel bolts or starter engaement.

I know what do do about those. I can fix that just fine. I have an escort drive coming in a week or so.

 

[SenorNoob]

4.0 Automatic starter fits right up with the 2.9 clutch and is a permanent magnet type starter so slightly more efficient. Also smaller.

 

[Project88]

I replaced the drive in the aftermarket starter since it was basically brand new 4 years ago and still starts and rolls over besides the grinding and non engagement put a 1986 escort drive in it with 11 Teeth not to downplay the whole 4.0 starter but I tried that already 4 years ago it took all of 15 starts for the gear tooth to shatter on it. If I have a picture of it I'll put it to this thread.

 

[Project88]

I replaced the drive in the aftermarket starter since it was basically brand new 4 years ago and still starts and rolls over besides the grinding and non engagement put a 1986 escort drive in it with 11 Teeth not to downplay the whole 4.0 starter but I tried that already 4 years ago it took all of 15 starts for the gear tooth to shatter on it. If I have a picture of it I'll put it to this thread.

Here's that starter from 4 years ago. After this incident I swapped out the bellhousing and starter bolts and starter.
Also while I was underneath my bronco yesterday I found I could put the bolts in without taking loose the transmission again so when the weather breaks in va and I have some time off I'll be under it fixing the pressure plate and all