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#130413 - 16th Feb 2005 9:29pm Clutch Problem
DavidB Offline
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Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
I'm currently sorting new stuff in engine, I'm also changing the clutch for a Black Diamond variety.
Only I would if I could get the input shaft out.

Here's what you have to do:
Take the transmission end plate off
remove the circlip off the input shaft hole
take the little nut out
and (as Hayne's manual says) simply pull the input shaft out.
However, Hayne's works on new cars, not 100k+ motors. It's stuck firm and I've reluctantly used a slide hammer, it still won't budge.

I understand if I loosen the gearbox bolts a bit, it might free it up. It's the last thing to do before I get the motor back on the road.

Any ideas??
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#130414 - 16th Feb 2005 9:34pm Re: Clutch Problem
DavidB Offline
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Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
Here it is:

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#130415 - 17th Feb 2005 2:24am Re: Clutch Problem
Scooby Offline
Forum Veteran

Registered: 9th Nov 2003
Posts: 5327
Loc: Birkenhead, Wirral.
Looking at that picture you havnt removed the little Torx head bolt ????

I have a special slide hammer that screws into the shaft mate.

They do become tight but i find if you screw the slide hammer in and get two pry-bars (One either side) you can prize the shaft out. They come out in the end mate doh

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#130416 - 17th Feb 2005 9:10pm Re: Clutch Problem
DavidB Offline
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Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
The head bolt is out, it's a little 12 torx with a 1 cm thread.

I'm going to try the slide hammer thing you said. It is only the splines keeping it in isn't it?
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#130417 - 18th Feb 2005 1:54am Re: Clutch Problem
Scooby Offline
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Registered: 9th Nov 2003
Posts: 5327
Loc: Birkenhead, Wirral.
yeah mate, if you carnt pull it out, try pushing it in (Hitting it inwards with a hammer) to get the shaft moving, once it is moving then work it backwards and forwards until it comes right out.

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#130418 - 17th Mar 2005 11:01pm Re: Clutch Problem
DavidB Offline
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Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
After three weeks of trying various methods, I got a crowbar, put a bolt in there, and gently 'levered' it out. I put those little clamps on the clutch, but they're the wrong size!! Retired, as it was getting far too late.
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#130419 - 19th Mar 2005 8:10pm Re: Clutch Problem
DavidB Offline
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Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
Okay, 'recovered' the clutch, it's in A1 condition, however, I touched the thrust bearing and wahey, it's raining ball bearings. The race had totally cracked into three bits and was dry inside, I could barely turn it. I put the new items back in, and hammered the input shaft into place...

I can't get it into gear! Now what? I've knackered my gear box haven't I?
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#130420 - 20th Mar 2005 3:41am Re: Clutch Problem
scoop Offline
Wiki Addict

Registered: 18th Nov 2004
Posts: 7238
Loc: Leuchars
oh no! gutted m8, is this on the GSi or the cesaro???
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#130421 - 20th Mar 2005 7:33pm Re: Clutch Problem
DavidB Offline
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Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
It's the GSi!
Fortunately, a bit of oversight on my part. I'd acidentally knocked it into fifth gear. The fifth cog is located outside the main gearbox, and just knocked it into gear when I was messing about. Just pulled it out, and it was fine!! hehe.

Car is now back on the road after being sat on the drive for two months, with an odd looking replacement grille replacing my stolen one.
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#130422 - 20th Mar 2005 7:38pm Re: Clutch Problem
Dazza Offline
Forum Master

Registered: 10th Nov 2003
Posts: 2899
Loc: Birkenhead
Good to hear its sorted now matey laugh

At least its mobile, u can worry about that rare grille at a later date
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#130423 - 20th Mar 2005 7:45pm Re: Clutch Problem
DavidB Offline
Wiki Guide

Registered: 7th Dec 2003
Posts: 5591
Loc: Bebington, Wirral
happy
I've actually got one, but haven't got round to spraying it red yet. smack
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