Help! Clutch Lever Cross Shaft Installed Backwards

earossi · 02-03-2012, 01:52 PM

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 · Henry Schmidt's Garage

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 · Henry Schmidt's Garage

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

I had no idea they were attached. So bite my head off for trying?

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 · Henry Schmidt's Garage

Quote:

Originally Posted by earossi

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

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

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