4g61t.org

Ok guys, just dropped my tranny for the third time this week. Finally found the issue, but don't know how to fix it... My flywheel is grinding against my bell housing. Don't know if this is my only problem though.

1. All this started when the other day I was at a redlight, shifted from neutral to first, car made horrible grinding sound soon as I got it into first and killed itself. Had to be towed home.

2. Ordered a new clutch set, thinking this was this issue, but was confused as the clutch in the car is only around 5 months old. When replacing clutch noticed HUUUGE gashes on the inside of the bell housing, right around where the flywheel would spin. Edge of flywheel teeth are slightly worn flat

SOO, I tested the car today after putting it all back together.

1. When taking off, car kinda hops for the first few seconds, then goes fine.

2. Grinds going into reverse, and when I get into reverse car immediately grabs and kills itself. All while I have the clutch depressed.


Had horrible luck recently with everything to do with the tranny and clutch. To me, it seems like to clutch isn't properly working, but I can SEE it working if I have a friend push the clutch while I watch.

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1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD

Seriously like this close to selling my colt....

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1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD

Dont sell it.

Take a week to really think about it.

Then come back to it.

It is a simple problem, just got to figure it out.

Sorry i couldnt help.

I've been screwing with this for a week lol. I wouldn't want to sell it that bad if this wasn't my DD. I'm a fuel pump and interior away from being done with my Porsche, but I'd like to not drive it on the salty roads. period.

The Colt pretty much runs now, but the flywheel is grinding BAD, but once I'm up to speed it doesn't seem to be a huge issue. Starter is also screaming with use, I'm sure it has something to do with it.

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1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD

Check and see if your starter bolts are tight, or striped.

Or the fly wheel bolts may be lose.

Flywheel bolts are loose OR clutch plate bolts are loose OR your tranny bolts are nonexistent (remember to put them in?) OR you had/have some debris in the bellhousing OR your crank is broken.

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Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd

i had this same issue!!!! i couldnt understand why for the longest trannny came off then back on untill i was like efff it! i just put spacer in each tranny bolt and it fixed that ..... been fine ever since

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Until you are faster than I am making more power or doing something to make me wonder if you are smarter than I am please leave me alone.David Buschur

Interesting issue, I believe it is possible to install the clutch disc backwards, not saying that's your problem though. You should probably get new flywheel if the teeth are damaged as well as a resurface and a new starter if those teeth are damaged too. Did you torque the flywheel bolts to spec in a star pattern? Is your clutch master rod properly adjusted? Are all of the housing bolts and dowel pins proper? You're going to have to remove the tranny and find the error.

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89 Mirage Billet 20g 63t 12.4@120 417whp 400wtq @ English Racing.
89 Colt GT E316g
06 Silverado SS
07 ZX6R

The tranny has been removed three times in the past week. Heres what I have checked:

Flywheel bolts are torqued correctly

Starter does need to be replaced, but works and I don't see how it could cause the flywheel to hit the bellhousing. Bolts are tight.

Clutch and pressure plate are brand new, as well as throw-out bearing, all installed correctly, double checked.

Was missing a bottom tranny bolt, went to Ace Hardware, got replacement, still grinding issue.

Clutch master is new and properly adjusted, checked multiple times

No debris in the bellhousing

Crank could be broken, but I don't think I'd be able to drive it up and down the street with a broken crank, would I? Top speed of around 45. Could still hear slightly grinding, but ran normal once out of first gear.

Anyone have a spare KM200 transmission they could get rid of?

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1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD

You didn't mention the dowel pins, are both in place?

I didn't have to remove any dowel rods/pins when I removed my transmission. Didn't have to when I swap this tranny onto my new engine. Where can I find replacements/specs? and Where do they go on the tranny?

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1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD

Any big dsm shop will have them, try one that specializes in transmissions.

_________________
Had a:
1991 Eagle Summit ES Hatchback - 4g15 12v 5spd
1991 Dodge Colt -4g15 12v 4spd
Have a:
1978 Oldsmobile Cutlass - 468BBO TH350
Round 3:
1990 Dodge Colt-4G63T 5spd

Any transmission shop or machine shop, and even parts stores with lots of hardware may have them. Best to call around first. Heck I just realized that those dowels may be solid pins versus being large roll pins like for cylinder head to block deck alignment. Same still applies, check around by phone after measuring the diameter, and then order if you have to.

On a 1.6 there is two alignment dowels/roll pins mounted in the motor.
It's been awhile since I've dropped a transmission out of a 1.5. Only picture
I have of the 1.6 shows the roll pin on the bottom right. Other pin is bottom left.

I made the video I recorded public, so you guys can get a better idea. Read the description to see what I've done so far. As far as the dowel rods, I never had any in the first time I swapped the engine a couple months back, so I'm doubting that. But, I still called a couple shops, both quoted me around $500 to re-make the dowel rods. I'm trying to exhaust any cheaper form of fixing it I can. I figured if it was the dowel rods, it'd also make the grinding constantly.

Anywho, here is the link:
http://www.facebook.com/photo.php?v=2647719240867

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1991 Dodge Colt - 1.5L 4G15 - Swap Project
1989 Dodge Colt GT - 2.0 4G63T - Racecar
1995 Honda Prelude - H23A2 - DD