replace the clutch and flywheel on 1989 3d GL 4 by 4 it is now smoking on start up in the clutch area. not exactly sure what is going on I believe I may need to adjust the clutch tension cable and the idle . I would appreciate some insight from someone who has done this before or understands how this is supposed to work

It's smoking just sitting there at idle in neutral?

Whenever you pull an engine out and put it back in you're gonna have smoke on startup. You got your greasy paw prints all over exhaust parts, you spilled some coolant over the top of the engine, you dropped a zip tie on the cat converter... etc. All that stuff is gonna smoke for the first few minutes when you start the engine.

 

The clutch really doesn't have any way of slipping when it's sitting at idle in neutral and as such shouldn't be the part making smoke. The clutch cable is properly adjusted when you have about 1/8" - 1/4" of forward/backward  play at the clutch fork. 

Thank you for you response. Pulled the engine, turned out the flywheel was scraping against the housing. Pilot bearing needed to be ajusted. About to put it all back together! All of this was much easier the second time around. Any idea what the torque specs are for the flywheel and the pressure plate.? I may have had the wrong numbers

I don't have my FSM up here at school, but IIRC the flywheel is around 55 ft/lbs, and the PP is something like 11.6 ft/lbs.

 

Are you missing the alignment pegs between the engine and transmission? There should be no adjustment needed of anything. What exactly do you mean by that?

How do you adjust a pilot bearing? And what housing was the flywheel scraping against??

Maybe the friction disc wasn't aligned properly in the pressure plate you mean? Even that I couldn't imagine... Scraping anything really..

 

Whatever though, if it's fixed it's fixed. What you describe as the problem doesn't sound very possible though lol

If the clutch disc wasn't aligned, it would have been impossible to mate the engine and transmission and start it up anyway... Those plastic alignment tools can be particularly miserable, though. My alignment tool is a cutoff input shaft of a broken transmission, it works great

the smoking and the sparks were from the new flywheel scraping against the bottom of the housing, wasnt that big of a deal once we figured out thats what was happening. Now, as far as the clutch not working, this was because Orileys auto parts gave us the wrong parts again. The pilot bearing wasnt touching the PP. Returned everything that we purchased from O'rileys. Then we went to NAPA and ordered our clutch set,  guna pick it up tomorrow. Going to put the old flywheel back on after it is machined. I will let you know how everything turns out!

The only thing for the flywheel to possibly hit is the little dust shield on the bottom. Unless you're using an EA82 flywheel in an ea81 motor. And you must be referring to the throw out bearing. The pilot bearing doesn't come in contact with the pressure plate. The input shafts goes into the pilot bearing which is installed in the flywheel.

Turns out I am a big dummy... Its a ae81.

call it an EA81 and you are just a little closer to the mark