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Patrick
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Clutch Fork Pin Removal - Another Thread...
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1984 944 NA, constant tinkering |
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Driver
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That's pretty ingenious. I hope I never need to refer to this thread lol.
GHEN
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'87 944 |
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Patrick
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Thanks.
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1984 944 NA, constant tinkering |
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Coeur d'Alene, Idaho
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Well done. Wise to use a larger slide hammer that's built well like that one. I had the same struggle and bought a smaller one figuring 'how hard can that thing be in there'. Well I should have continued that thought with '....after 34 continuous years?' It was a struggle and I bent and damaged the slide hammer's connections but the pin finally gave. Fortunately its a hobby car for me so I was able to spray Kroil on it and let it sit.
Yes, this is a part of that job worthy of respect, patience, and not to be rushed.
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84 944, 87 Vanagon, 88 Mitsubishi Van Wagon, 88 Supra Targa, 1990 Audi 90 20V Quattro sedan, 1992 Lexus LS400, 1993 LandCruiser, 1997 LandCruiser, 2017 Subaru Outback. |
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Patrick
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I think I watched Jurgen and Van Svenson's tutorial several times each prior to picking up the first wrench, thanks guys!!!!
Rear main seal and pilot bearing removal is next. I did purchase the proper pilot bearing removal tool a while back and the Arnnworx rear main seal insertion tool arrived over the weekend (just another excuse to buy good tools...). ![]() BTW: It was a real bugger removing the bellhousing, partially because I missed one of the starter cable clamps located near the top drivers side and offset from the reference sensor mounting plate. Imagine my surprise when I pulled the clutch and found this: ![]() There's still some meat left but the throwout bearing was tired and noisy. Besides, the torque tube was whining but I guess after 35yrs and 133k miles, I'd be whining too...
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1984 944 NA, constant tinkering |
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Patrick
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Continuing work:
1. Flywheel out for re-surfacing; the thickness is currently at 14.25mm so it should be fine after machining: ![]() 2. Rear main seal and pilot bearing out: ![]() ![]() 3. Engine cleaned up: ![]() 4. Lower balance shaft removed, found a crack in one of the bearings: ![]()
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1984 944 NA, constant tinkering |
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Patrick
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Flywheel came back from the machine shop today!
about 0.004 was cut leaving over 14mm thickness (well within spec). ![]()
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1984 944 NA, constant tinkering |
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Driver
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May I ask how much the machine shop charged you?
GHEN
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'87 944 |
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Patrick
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$65.00
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1984 944 NA, constant tinkering |
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Coeur d'Alene, Idaho
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How do you think the crack formed? Was it an original factory bearing? Good catch.
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84 944, 87 Vanagon, 88 Mitsubishi Van Wagon, 88 Supra Targa, 1990 Audi 90 20V Quattro sedan, 1992 Lexus LS400, 1993 LandCruiser, 1997 LandCruiser, 2017 Subaru Outback. |
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Patrick
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No idea but it appears that this clutch is the original one unless it was replaced very early in the car's life. What amazes me is that the rubber center is still intact and in pretty good shape for a 35+ year old car with 133k miles.
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1984 944 NA, constant tinkering |
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Patrick
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Work completed today:
Pilot bearing & RMS installed; I used the Arnnworx RMS tool which made the install quite easy. ![]() Flywheel installed: ![]() Clutch disc & pressure plate mounted and installed: ![]() Replaced fork needle bearings: ![]()
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1984 944 NA, constant tinkering |
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Patrick
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Not much happened this week but I did get the exhaust headers bead blasted and ceramic coated and the balance shaft bearings arrived yesterday.
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1984 944 NA, constant tinkering |
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Registered User
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Excellent work...quality garage ethic very evident. John (NE Connecticut)
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Patrick
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Thanks. My OCD gets the best of me everytime! Besides, nothing's worse than having a couple/few extra parts when finished...
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1984 944 NA, constant tinkering |
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Patrick
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Question Guys: I'm ready to install the bellhousing and it's getting hung up on the ref sensor boss, up in the tunnel. Is there some trick to do this? Removing it was also a bear but got it done... I'm missing something and appreciate any input.
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1984 944 NA, constant tinkering |
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Patrick
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Never mind, I figured out that if I tilt the front of the engine just a bit, the bellhousing goes on without too much hassle.
![]() With new pin & locking bolt/nut: ![]() Even had some time to install the balance shaft/housing; re-installing the motor mount bracket was such a joy! ![]()
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1984 944 NA, constant tinkering |
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Patrick
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Spent some time with her yesterday so I buttoned up the front...
![]() Re-installed the ground wires; can someone please let me know if this orientation is correct? I neglected to document this prior to disassembly, thanks! ![]()
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1984 944 NA, constant tinkering |
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