At present i am trying to fit a second hand gearbox to my 2004 hyundai trajet crd. I am trying to fit the gearbox to the engine with the thrust bearing fitted to the pressure plate. . . .i now know this is not going to work could anyone please tell me the correct way to put this thing back together?

 

This is a schematic to the clutch on a 2004 Elantra drive train showing the relationship of the components. The Trajet was never marketed in the U.S., but some Trajet literature suggest the two models did share some engine and transmission options. Most manual tranny schematics would show the same basic arrangement, regardless of make and model. The release or throwout bearing simply slides over the input shaft arbor while the tranny and engine are bolted together. No pressure can be applied to the pressure plate by the throwout bearing until the release fork and slave cylinder are installed.



What is not shown is the splined input shaft on the transmission. The splines on the input shaft will fit through the center of the clutch disk. The very tip of the input shaft is milled smooth to fit inside a pilot bearing that is installed in the center face of the flywheel. If you removed the clutch from the flywheel and did not use a pilot bearing/clutch disk alignment tool to center the splines cut in the clutch disk when bolting the clutch/pressure plate cover to the flywheel, the transmission input shaft will not line up properly with the flywheel. In other words, it will not go back together no matter how hard you try.

 

Thanks for posting the schematic diagram for the clutch. I needed it badly. Serves great help!