deliriousga

This is really killing me. For some reason the short drive shaft won't slide out to allow the clutch pack to drop. I don't remember this being such a huge problem before, but for some reason everything is being difficult today.

Is there some little thing I'm forgetting to make this easier? The top of the arm is popped off the ball. The bolts for the pressure plate to the flywheel are out. The clamping sleeve bolts are out and the sleeve is off the short shaft. The angles are in the clutch pack so it's compressed. Any ideas?

I'm soooo close to getting the darn torque tube out but too frustrated and afraid I'll break something so I'm dropping it for the evening and hoping there's something I missed for tomorrow night. Thank God our neighbors are going to let us borrow their car to get to work tomorrow, but I'm dreading getting back to this after work.

TIA!!

worf928

Arm's off. All PP bolts are out. Sleave bolts are out. Clamp is pushed back into the TT. Yes?

How is the sleave off of the shaft? You mean that the sleave slides back and forth?


So, the intermediate shaft is seized to the pilot bearing? If so - BFH. Watch your head.

You have the starter loose too right? (Starter needs to be loose and withdrawn from the ring gear by about 1/2" or it will snag the clutch.)

ZEUS+

Worf you beat me to it !!! Sounds like shaft seized in bearing.

ErnestSw

Been there, done that except the half shaft was seized to the inside bearing race only so the pack was loose, but couldn't fall. You're going to have to re-hang the clutch assembly on the upper ball, or support it from below and get the weight off of it. Then you'll need to get some sort of clamp around the short shaft and use the clamp to force it back with a slide hammer or a sledge hammer and a BFS (Big F***** Screwdriver).

deliriousga

Yes

The clamping sleeve is off of the intermediate shaft. It's slid back into the torque tube.

Starter's loose and slid back.

If it's fused to the pilot bearing, how in the world do I get it out of there? It wiggles up and down and side to side, but just won't slide back toward the TT so I can drop it.

worf928

OK. I thought you were referring to the guide tube. You've got the guide tube loose too right? And can you move the guide tube?

It is also possible that the i-shaft is seized to the friction disc. I just finished a clutch R&R where that was the case. I seem to recall that I was able to get the pack out with some prying-back of the PP and/or a BFH, BFS.

See what Ernest wrote above. You'll want to get the clutch pack secured. I suggest a few of the PP bolts. You do not want the pack to just drop (on your head). Then you need to figure out a way to wack the i-shaft with a BFH-type of tool. (BFH = big eff'in hammer.) I've not had to do this so I cannot offer the BTDT viewpoint.

Maybe you can reattach the coupler to just the i-shaft and then, using a bit of wood to protect the coupler, give the coupler a backwards wack?

EDIT: Oh yeah. One more thing: I hit the suckers (i-shaft and pilot bearing) with PB Blaster and let it sit for a while before attacking it.

AO

Make sure the guide tube is free like Dave says. Then if you can't move the i-shaft back, I'd put a couple of bolts back in as suggested, then clamp the sleeve back on the i-shaft ONLY. Then with a prybar, I think you should be able to lever it back using the fork as your fulcrum. Then, unclamp, remove the other bolts and watch out! Sometimes it's nice to have the starter in the way to keep that SOB from falling on your head!

worf928

werd.

deliriousga

The guide tube is already unbolted and slid into the pressure plate so all it's hanging by is the intermediate shaft. I have a jack under it so it wouldn't fall on my head. I'll order a new pilot bearing and try it again this weekend. The water pump for the Boxster will be here tomorrow so only one more day of "how do I get there" then hopefully after the weekend both are back and the Shark is driving like new again.

Thanks!

Mrmerlin

Hi reclamp the coupler to the small shaft and pry it rearwards, if this doesnt work them a hammer is next if all goes well the bearing should split and then the ***** will fall out and you can then remove the clamp and slide the coupler back and then remove as necessary of course you will then have an interesting time removing the outer race use a dremel to grind the race , Goodluck, Stan

ZEUS+

Have you been able to determine if the shaft is seized in pilot bearing or disc to shaft ? I have had to cut discs off shafts.

deliriousga

I'm pretty sure it's the pilot bearing. After getting all of the bolts out, the whloe clutch pack will slide out about 1/4"-1/2" like normal, but the shaft won't move.

ZEUS+

So you can get the disc to move on shaft ?

Lizard928

it is best if you leave the PP and discs bolted up to the flywheel for removing that shaft, however I would recommend that you rent/beg/borrow/cheat or steal a slide hammer, and with the torque tube down put the coupler back on the shaft and get the slide hammer on it, only one or two blows, she will come free.