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-   -   Help! Clutch Lever Cross Shaft Installed Backwards (http://forums.pelicanparts.com/911-engine-rebuilding-forum/655558-help-clutch-lever-cross-shaft-installed-backwards.html)

earossi 02-03-2012 01:52 PM

Help! Clutch Lever Cross Shaft Installed Backwards
 
I'm in the process of trying to separate the G50 trans from my 3.6 motor, and need to pull the clutch actuating fork cross shaft. The PO has the shaft installed backwards, so that there is no tapped hole in the end of the shaft facing out to use a puller on.

I know this has probably happened before, and would like to know the best way to pull the shaft out. I guess that I could attempt to drill and tap a hole into the end of the shaft that is exposed to me. I wonder if the shaft would just spin making drilling and tapping a hole a PITA.

What else can I do to get the cross shaft out so that I can split the tranny from the motor?

Thanks in advance.

Henry Schmidt 02-03-2012 02:06 PM

Lubricant and gravity?

earossi 02-03-2012 02:10 PM

Are you serious? I could spray Kroil in there, but then what? Motor and tranny are sitting on my workbench, so I can't easily tilt them.

Henry Schmidt 02-03-2012 02:17 PM

Ernie, I just reread your post and I guess my reading comprehension is in the crapper today.... Oh well, some days are better than others.............
Bruce has a good idea for separating them, good luck.

Flat6pac 02-03-2012 03:34 PM

Drop the starter and remove the clutch package. At least you can split the engine off
Bruce

earossi 02-03-2012 03:58 PM

Quote:

Originally Posted by Henry Schmidt (Post 6535625)
I had no idea they were attached. So bite my head off for trying?:confused:

Henry, with all due respect, I have owned and wrenched on Porsches for over 40 years, during which time I have have participated and depended upon this and other forums for advice. I am an amature enthusiast. While I have been a contributor, my knowledge does not approach yours, since you are in the business and have been an active and value added contributor for quite some time on this forum. However, when someone is in need of assistance, as I now am, your humor in response to my request for assistance has left me at a loss. What I was hoping for was suggestions based upon prior experience. What I got from you was flipant arrogance.

I apologise for this repsonse; but, frankly at this juncture the last thing I need is sarcasm or misdirected humor.

Respectfully,

earossi 02-03-2012 04:11 PM

Bruce,

I have the engine/tranny sitting on my workbench. I have the starter pulled. How, do I now pull the clutch without first pulling the cross shaft? Please clarify.

Thanks for your response.

Henry Schmidt 02-03-2012 04:30 PM

Quote:

Originally Posted by earossi (Post 6535801)
snip.....

I apologise for this repsonse; but, frankly at this juncture the last thing I need is sarcasm or misdirected humor.

Respectfully,

It wasn't sarcasm, I just read your post incorrectly. I'm sorry you're having a bad day but I was trying to help.

BTW: on the internet sarcasm is generally posted in green.

Eagledriver 02-03-2012 05:48 PM

I would guess you would remove the bolts holding the pressure plate to the flywheel.

-Andy

Flat6pac 02-03-2012 06:23 PM

Andy beat me to the answer
Bruce

earossi 02-03-2012 06:37 PM

Andy,

Thanks for your response. Can I access the pressure plate bolts through the starter access hole? I'm not down in the garage and can't visualize it. If so, I can bar the engine over and take the bolts out slowly. Then, when I separate the trans, the plate and disk should remain on the trans output shaft as I pull the trans, right? That will still leave the release lever and cross shaft installed in the bell housing. Is there access to the back side of the shaft so that I can tap it out once I have access to the interior of the bell housing?

earossi 02-03-2012 07:30 PM

Quote:

Originally Posted by earossi (Post 6536077)
Andy,

Thanks for your response. Can I access the pressure plate bolts through the starter access hole? I'm not down in the garage and can't visualize it. If so, I can bar the engine over and take the bolts out slowly. Then, when I separate the trans, the plate and disk should remain on the trans output shaft as I pull the trans, right? That will still leave the release lever and cross shaft installed in the bell housing. Is there access to the back side of the shaft so that I can tap it out once I have access to the interior of the bell housing?


OK. Took a look at it, and I can see that I can pull the pressure plate bolts one at a time. I am attempting to epoxy a bolt to the bare end of the cross shaft hoping that it will not take a lot of force to pull the shaft out. I'll give that a try first, and if that fails, I'll take your idea to remove the bolts holding the pressure plate to the flywheel.

Flat6pac 02-04-2012 04:29 AM

Thought, when you remove the steel retainer there is a fiber dust cover that comes off to reveal the threads of the cross pin.
Did you remove the dust cover with the steel retainer?
Bruce

earossi 02-04-2012 05:39 AM

Quote:

Originally Posted by Flat6pac (Post 6536538)
Thought, when you remove the steel retainer there is a fiber dust cover that comes off to reveal the threads of the cross pin.
Did you remove the dust cover with the steel retainer?
Bruce


Did not see any plastic cover or plug behind the shaft retainer. My car is a 98, so may be a little different than earlier years (I am finding that on other items as well). On the tranny, there was a plastic cover plate with a gooseneck down facing vent over the cavity in the trans case. Three bolts and the cover comes off. Removing the cover reveals a kind of triangular shaped cavity about 2" deep. There is the expected metal retainer held in place by one bolt. When I removed the retainer, I expected to see the threaded end of the cross shaft; however, what I saw was a shaft without a tapped hole. No other plastic or metal items in the cavity. I will look again this morning and try to take a picture.

Flat6pac 02-04-2012 08:35 AM

I was talking with knowledge of the late 911 and the C-2. Thants my references.
Bruce

KTL 02-04-2012 08:54 AM

That cross shaft is not hardened, so you should be able to drill it fairly easily. Just make sure to use a new bit and some cutting fluid.

Or else weld a bolt on to the end of the shaft? You certainly can't get the ground clamp onto the shaft itself. But the alloy case should be a decent conductor to get "continuity" to the shaft so you can weld on it.

earossi 02-04-2012 10:19 AM

Epoxied bolt worked great! Cross shaft came right out. Thanks all. Back to the teardown.

Do any of your guys have a source for the rubber ells and tees needed to rejuvinate the vacuum operated constols system on this motor? Porsche carries some of the fittings, but some them are marked as NLA. Those that are available are grossly expensive.

Eagledriver 02-04-2012 10:50 AM

I've found such "L's" and "T's" at Ace Hardware. They are for drip irrigation systems. Probably not the best quality for your vacuum system but they might be better than the old parts.

-Andy


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