Engine Drop - Can't remove clutch arm assembly

[Gordo2]

Folks,

I'm dropping my first motor tomorrow: 85 Carrera, following proceedures in my Bentley manual.

I can't seem to remove the whole clutch arm, or for that matter, figure out why I need to for the engine drop. I've been able to remove the lever arm from the splined shaft, but the rest of the assembly won't budge - its rusted to the clutch fork shaft.

Does this really need to be removed for the engine drop, or can I drop it and work on it once its out of the chassis.

Thanks, Gordo

[rsscotty]

If you are going to detach the gearbox, then you need to remove the clutch levers from the splined shaft that comes out of the gearbox . There are two levers. A small one comes off first after removing the circlip...the second comes off last..the longer one with the large conical spring. The tension has to be relieved before the second one will drop down. Do this by prying with a large long screwdriver at the end of the lever. You need to pry the lever towards the front of the car until the lever pops and relieves the tension. Keep your hands out of the way!!! Again, if you are not going to remove the gearbox then this is not needed to do.

[Flat6pac]

But the larger lever is suposed to be able to pivot freely once the spring tension is removed. I have in the past found it necessary to air chisel the shaft to remove the large arm. Using the point chisel on the bottom of the verticle bar the vibration will allow you to pull the arm down and off.
You need to clean the inside and lubricate well with anti seize before reassembly.
Bruce

[pete3799]

Also check to see if there's a roll pin about 1/2 way up the shaft.
Mine had one and needed to be driven out in order for the arm to come off.
I also couldn't get the arm to clear the crossover pipe so i dropped it with it on and loosened
the trans enough to get the arm off after.

[Gordo2]

Thanks guys,

I guess I was searching the wrong terms - I found loads of threads on stuck clutch arms (I was searching clutch release...). Appears I'm not the only one who has run into this problem.

I've hit it with PB blaster for the past 2 days. Hit it with a hammer and chisel; heated it and hit it with the hammer and chisel (made about 3mm of progress until my wife called out to my garage reminding me that it was 10:00 PM...).

Headed to harbor freight tomorrow - looks like I will add an air chisel to the shopping list.

Gordo

[Gordo2]

Two days of PB Blaster, two hours or so of heating, hitting and swearing, and finally giving up on the idea that it was coming off without beating the crap out of it... It finally conceded. I've had easier battles with horribly stuck brake pistons.

The carnage:




Gordo