Doug85.5944na

I've searched the previous threads and can't find what I'm doing wrong. What's holding the gear on? I removed the bolt that threads into the side of the gear into the shaft. I don't see a woodruff key. I've used a puller on the thing until the end of the shaft is flared and can't get it to budge. Help!

Sam Lin

Bolt in the middle of it, axial to the camshaft, It sounds like you just removed the bolt holding the rotor shaft. Pull the rotor shaft out with visegrips and look behind it for the little bolt. It's a cheesehead.

Sam

Doug85.5944na

OK, I see it. Thanks very much!

RedlineMan

Yes;

To be more descriptive, the shaft that the rotor attaches to is itself a separate part. It is held into the the cam gear with a small bolt. Remove that bolt and pull out the rotor sub-shaft. If the sub shaft is stuck, juice it good with pentrant and wait a while. If it still won't budge, a little heat to the cam gear snout will do the trick.

You will then see an internal 12 point bolt recessed inside the cam gear. This is what holds the cam gear on. Be prepared, because this bolt very often will not come off! If you strip it or it won't budge, take a drill larger than the 8mm bolt shaft and drill the head of the bolt off. Keep your face back because it often will pop off and go flying! The bolt shaft will then easily thread out by finger.

You might think I'm $hittin yah. I know it all sounds crazy, but I'm not. Just for kicks, find the bolt head and look at the back side. There will be a small ring about 1mm wide on the back of the head that is polished smooth and shiny. This is why it was stuck, and is called galling. That tiny little surface will withstand many dozens of pounds of force.

Believe it! I've got the T-shirts!!

Serge944

One thing to keep in mind...the camshaft is quite brittle. I broke mine off near the gear with my old engine while having fun disassembling the useless pos.

nine-44

I have had to drill the head off of more cam bolts than I have successfully removed. It's no big deal and I normally have a new bolt in hand when I plan to pull that bolt. They can be stubborn. Good luck

Granite 944

You might already have a good handle on all of this, from all the good, previous replies, but heres a picture of the parts after teardown I took at one time, if that might help.

Danno

Remember to pull that middle carrier piece directly outwards. Do not try to turn it even though it looks like a giant socket can fit over it. I've seen quite a few cams with damaged woodruff keyways because some gorilla tried to force that carrier piece off with an impact wrench. I just use some channel-lock pliers and pull it foward.

Definitely use an impact-driver to shock and loosen the cheese-head bolt holding the cam-gear onto the cam.

Doug85.5944na

Finally got it off. Granite 944, your picture made it clear when coupled with Danno's "remember to pull the middle carrier piece directly outward." oooooooooohhhhhhh, now I see.

Granite 944

Glad to hear it! Danno can always fill in the blanks I leave...........more often than not.........HOLES.