Lots of SRT Progress!

Sunday I spent some more time in the garage with my friends to make progress on the SRT.

After a few attempts, we were able to install the timing belt and line up all the timing marks correctly. We spun the crank a few full rotations to ensure that nothing was off, each time all the marks lined up exactly as expected. Once we were happy with the timing, we buttoned up all the belt covers and brackets.

Next came the AGP log style exhaust manifold. I purchased new studs for the manifold, and we used new grade 10.9 bolts instead of reusing the old factory manifold bolts. It was easiest to quickly remove the alternator to get to the bottom right bolt and torque it to the factory 250 inch-lbs spec. If the motor was in the car, I wouldn’t have taken the time to do that.

At this point the engine was ready to come off the stand to install the clutch and then the transmission.

ACT Xtreme 6-puck was installed using the non-modular bolts from the 95 neon.

I used the ACT supplied high-temp grease to lube the input shaft collar, splines, and other points in the bell housing. We later decided not to lube the splines so that was wiped off.

And then the fun began…

I got in a little bit over my head and used a bolt that was too long in an attempt to bolt the transmission to the block. Since the bolt bottomed out, it pulled all the threads out of the hole in the transmission case. That ended Sunday’s wrenching session.

After some research, I purchased a Helicoil kit and dril bit to repair the threads. Tuesday night I decided to skip the Las Vegas SRT Club weekly meet to continue work on the car. The thread repair was actually very easy and pretty much went without any problems. The way a helicoil works is by drilling and tapping a larger hole in the place to be repaired, then special inserts that look like springs are threaded into the hole to replace the threads for the original bolt. If you’re really interested in the process, this video from YouTube gives a quick overview.

My repair. The supplied tap had to be modified slightly to fit the tap handle we were using. Besides, sparks are cool.

After the threads were repaired, the transmission bolted right up. With the engine supported on the hoist it was pretty easy to line up all the holes and snug it down.