Removal clutch cross shaft g50 1988 carrera

[bouncer]

The engine and transmission have been removed in one piece and now I need to remove the clutch cross shaft to separate the two. What size bolt and thread fits to pull the shaft out and what tool is best used to do it?

Secondly, once separated, where do I attached the chains of the engine hoist to be able to raise it to my engine stand that does have the appropriate Porsche coupler?

Mike

[Dpmulvan]

You should buy a Bentley book.

[boyt911sc]

Remove the plastic cover to expose the bracket holding the cross shaft. Loosen the 6-mm fastener, bracket, cover, etc. Then thread a long (approx. 3") 6-mm bolt and slowly wiggle out the cross shaft.

The suggestion to get a Bentley Carrera manual is a very good advise. The Bentley manuals have many typo's but over all they are very helpful to DIY'ers. Keep us posted.

Tony

[bouncer]

Thanks Tony; appreciate the instructions and the reiteration as to the Bentley manual.

Mike

[boyt911sc]

Mike,

There are many ways to get the engine up in the air for engine stand installation. I'll show mine:

Front side of engine:


Rear end of the engine (no yoke):

Install the engine yoke and use it to lift the rear end of the engine. I use a load lever from Harbor Freight that makes the load even or parallel to the ground for easy installation on the engine stand.

Tony

[KTL]

Often times that shaft doesn't want to wiggle out and you have to yank it out with some impact force. Like Tony said, a long M6 bolt is helpful. To that point, get a long length of M6 threaded rod that will extend well beyond the bellhousing and exhaust heater port. Then you can put a nut near the end of the threaded rod & clamp a pair of vice grips next to the nut. Tap on the vise grips with a hammer to act as a slide hammer that will pull the shaft out.

Also its a good idea to spray some penetrating lube into the shaft support areas in the bellhousing. This can help to release the shaft if it has any corrosion on it that will obstruct the shaft from sliding out.

[boyt911sc]

Originally Posted by KTL

Often times that shaft doesn't want to wiggle out and you have to yank it out with some impact force. Like Tony said, a long M6 bolt is helpful. To that point, get a long length of M6 threaded rod that will extend well beyond the bellhousing and exhaust heater port. Then you can put a nut near the end of the threaded rod & clamp a pair of vice grips next to the nut. Tap on the vise grips with a hammer to act as a slide hammer that will pull the shaft out.

Also its a good idea to spray some penetrating lube into the shaft support areas in the bellhousing. This can help to release the shaft if it has any corrosion on it that will obstruct the shaft from sliding out.

Kevin,

When I inspected the clutch of the '87 Carrera before taking it to a cross country drive, I only used a 6-mm x 1.0 bolt attached to a vise grip. With very minimal effort, I was able to get the cross shaft out for inspection. It was the updated version and reassembled them back together. I was not able to use this gizmo;


Above is my CIS fuel injector puller with a 3-in. long 6-mm x 1.0 bolt and was ready in case I encountered some resistance in getting cross shaft out. Luck was with me at that time. BTW, I read a lot of Kevin's previous posts about the cross shaft upgrade. Plus I have his email and phone number to call if needed. Thanks.

Tony

[Jeff Alton]

Sometimes they come out with hand pressure, other times a slide hammer is required. All depends on the bearings/bushings the rod rides in...

Cheers

[Dpmulvan]

find two other people and you can lift the motor onto the stand with little effort

[hcoles]

consider finessing it out with light forces, penetrating oil and twisting - I suggest you don't want to put undue stress on the ears. Those ears have been known to break in service.

I reinstalled with a hard chrome shaft and IGUS plastic bushings - so far so good after 5 years or so. It is my experiment - I don't want to guarantee it.