Well, that was fun. Some things I learned while removing and replacing the gearbox and engine:
It's just too easy to change the cambelt with the engine out of the car. I set the belt tension to 100hz, the low end because I know the belt will whine when the engine is warmed to operating temp. Engine back in, engine running - belt whining! So, under the car I go and I'm getting good at the fine adjustment required to keep the whine out of the belt.
It's easy to bleed the clutch slave, but after wearing out my wife and endless hours of pressure bleeding, I gave up and took Atwell's advice - pushed the clutch pedal full down with a stick and left it overnight - works perfectly!
If you are going to do the belt, spend another $120 for the 104 green dot sprocket from JAE. I had one on the intake from the last cambelt change (robbed it off the oil pump shaft) but with the exhaust green dot installed, there is a noticeable difference in power. Very well spent bucks in my opinion.
A broken coolant level sensor will set all sorts of code 26, A&B, CEL etc. - and Freescan tells you it's everything under the sun - except the coolant sensor. Another $120 from JAE and it's back to normal. (Is everything $120 at JAE?)
Use the moist bread method to remove the spigot bearing - but tell your wife first why you need the bread because it's fun to watch her face and then the eye roll. Don't forget to tell her you invented it, just something you thought might work 😉
RTV Ultra Black on the roll pins - I was fearing them, but they went in OK - took quite a bit of hammer, surprised at first - but they went in and nary a drop leaks from the engine. Oh yeah, tighten the transaxle drain plug after you put it in finger tight - and before you fill the box. Duh. JAE threw the new roll pins in for free 🙂
The Redline MT90 that came out of the box after 4 years was almost as clear and pink as the stuff going in. I love that stuff.
Don't forget to buy some Dexron II for the power steering - had to make a special trip before I could start the engine.
Amazon same day is great when you lose the transaxle mount bolts - they were here faster than the time I spent looking for where the hell the originals went. They are not small bolts - but they are gone forever and I hope they are happy in their new lives somewhere.
Car runs great and the new clutch disc is notable as is the power between 2500 and 5000. 🙂