Clutch release lever pivot shaft removal HELP!!!!!!!

drfatz · 06-29-2005, 07:12 PM

I'm replacing my clutch using Clark's Garage instructions. Well I was trying to remove the release lever pivot shaft using the suggested 8mm Bolt...well the bolt has since sheared off, I've managed to remove the shaft about 1/4" but now it will not come out. So, I can't thread in a new bolt, and vice grips, pry bar, and hammer arn't doing anything. I'm wondering how long this shaft is and why do I need to take it out? If its absolutly nessecary then HOW DO I GET THE DAMN THING OUT!!!! This is really frusterating so any help would be much appreciated

WaA420 · 06-29-2005, 07:38 PM

What I do when this crap happens is to take out the nine pressure plate bolts through the holes in the bell housing. After you get it off you can take a drift pin and drive it out from the top.

DannoXYZ · 06-29-2005, 08:36 PM

Did you undo the locking bolt that goes into the side of that pivot pin???

drfatz · 06-30-2005, 05:21 AM

I removed the locking bolt before I began trying to remove the shaft. WaA420...I'm a little confused about the mechanics behind doing what you suggested. Currently the torque tube has been pulled back but the clutch housing is still bolted on. If I understand you correctly you suggest removing the pressure plate bolts through the housing and then driving out the shaft....how does one go about driving out the shaft? I imagine you would need to get behind the shaft to drive it out, yet the entire engine is in your way?

IceShark · 06-30-2005, 08:55 AM

No, that isn't what he is suggesting. First pull the torque and drive shaft back all the way. Then you can get at the 9 bolts that hold the PP to the flywheel through the starter hole. Then pull all the bellhousing bolts and you can pull the bellhousing, PP and TOB all as one unit. Then work on driving out the pivot pin from the inside on your work bench.

Actually, when you get everything loose the clutch fork fingers may slip out of the throwout bearing but that doesn't really matter as the bell housing is goint to come free either way.

DannoXYZ · 04:34 AM

There's also three holes on the periphery of the bellhousing where you can undo three pressure-plate bolts at a time, turn it slightly and do the next three, then the final three...

Zero10 · 06-30-2005, 09:06 PM

Yep, once it's out, there is a pin that goes straight into the bellhousing, drive it in until it falls out the inside (maybe 4mm in diameter?), then use a 3/8" long extension, and hammer the pin out from the top. It's pretty self explanitory once you get it out and apart.

You can remove the pressure plate and bellhousing as one piece, just take out the 9 bolts, and you're good to go

drfatz · 07-05-2005, 06:25 AM

I really wish the Clark's Garge instructions had said that the PP and Bellhousing could be removed in one piece. Now I may have to get a new pivot shaft seeing as the end is rather beat up after trying to remove it. Anyone know where I can get just a pivot shaft? Pelican sells the whole shaft and assembly for $300, but of course I only need the shaft. Appreciate it,

-GD

ronniebaldino · 07-05-2005, 07:15 AM

I may have got lucky but after I sheard off the bolt I was using I ended up wiggiling the bellhousing enough that it came off without having to take the pressure plate clutch flywheel off with it. I think I was just lucky though. Take off all the bolts holding the bellhousing on and try to wiggle the release fork free of the release bearing. If that doesn't work then take off the flywheel.

IceShark · 07-05-2005, 08:29 AM

Clark's description on how to remove the shaft is a disatser waiting to happen on a 15 to 20 year old car. The best way is to get a 2 foot threaded rod, I think it is 8mm but Clark's has the size, and make a slide hammer out of it. Lock a couple nuts on the end, a big thick washer, and something heavy as the slide hammer. Like a 2 pound hammer head. Or just a block of steel and drill a hole through it. Then you have enough travel and mass to get the hammer going and it will come out pretty easy.

As far as replacing the pivot shaft, go down to your local machine shop and be nice and polite. They can probably pull the machine screw out of the hole. If not, they can likely custom make a whole new shaft for far under $300. Heck, I had an 1 1/4" diameter propeller shaft with tapered end and threads custom made out of monel for a little over 100 bucks. And that was a 3 foot long shaft out of far higher quality material than you need.

Britwrench · 07-05-2005, 10:58 AM

The release shaft, part number 951 116 133 00 is about $35.00.
The lever, part number 931 116 085 00 is about $300.
If only replacing the shaft, and it always needs replacing, also change the bearings, pt number 999 201 213 00, which are about $10.20 and you need two.

pokey · 07-05-2005, 11:00 AM

"Heck, I had an 1 1/4" diameter propeller shaft with tapered end and threads custom made out of monel for a little over 100 bucks. And that was a 3 foot long shaft out of far higher quality material than you need."-IceShark

The monel alone should have cost more than $100. Let alone the machine work and balancing! I want the name and address of that shop.

drfatz · 07-05-2005, 12:02 PM

Where can I get a hold of just the shaft (have bearings already)? Local P dealership?

IceShark · 07-05-2005, 12:26 PM

The records are of that shaft job are on Palau, which is a western island about 6 thousand miles off Hawaii.

I'll try and find them if you reaaly want. The place is in Hudson WI just off I94.

As I noted, be nice. Goes a long way in getying help

Britwrench · 07-05-2005, 05:21 PM

If you have a local Porsche independent shop or offical dealership, either can get the parts. Or go to any local independent German car shop. They can order it from the wholesaler they use.

IceShark · 07-05-2005, 06:13 PM

The point is he can get this done without spending a ton of cash.

Yes, he did screw up, but not all is lost. He can fix it easy.

pokey · 07-05-2005, 06:56 PM

Quote:

Originally posted by IceShark
The records are of that shaft job are on Palau, which is a western island about 6 thousand miles off Hawaii.

I'll try and find them if you reaaly want. The place is in Hudson WI just off I94.

As I noted, be nice. Goes a long way in getying help

I take someone is off cruising. That's my goal. only I'd rather head for the Carribean and the Med.