944 engine removal- engine stuck on spline
 

Hi guys, I was hoping you can help.
When removing my early 944 engine I have persuaded it to the far right of the car (250mm)near the spoiler. I knew something is wrong, so I checked a spare torque tube and there is only 150mm of shaft and of that is 80mm of splined shaft.
The engine is reluctant to move back wards and its obvious the splined part of the shaft is still caught in the engine. Looking through the inspection window at the diff, The shaft is still attached and has moved a inch. I`ve always used engine penetration oil.
Has anyone had this before?
What`s my solution, remove the clutch housing bolts and see if I can disengage the shaft. The other solution is jack up the back end and remove the back suspension and the torque tube. Any solutions, or advise is appreciative.

Engine removale information:
http://www.clarks-garage.com/pdf-manual/eng-01.pdf

Try lowering or raising the engine to release any up or down tension that may be on the torque shaft, then put the engine back in up to the bellhousing. Make sure the torque shaft rear coupler bolts are tight if you can get at them.. Then, then try to slide the engine out again, nice n level, you don't want it to tilt/pitch at all while sliding it forward as that will bind the torque shaft splines on the clutch disc and tug on the torque shaft.

u can also try tilting the torque tube carrier up and down. use small jack or wedges. it has to be angled perfectly. also try using a ratcheting strap to hold it tight as u jiggle.

As above, and also take out the radiator fans, radiator and AC condenser to give you more room. Pop up the headlights as well. I agree - realign the engine with the TT and slide forward. It should come.

I love that kind of talk from you, Slam!

drop the trans and slide the tube back, will only take like 5 minutes

Heh. Rasta, it'll only take, like, 5 minutes...

thanks guys for the feedback.
Relevant info that I forgot to post, that the reason for the engine swap is that the thrust bearing is knackered. When I had my foot on the clutch pedal, there was a terrible knocking sound.
*****I wonder if this is the reason for the spline not disengaging from the engine?****
Previously I`ve got two 944 engines out in record time but this one is stubborn.
I`m curious to take of the bell housing off and have a nosey.

When you say the thrust bearing do you mean the clutch disc center? or the clutch spring/clutch throw out bearing?

Your clutch disc could be stuck on the splines if the center was really bad.

There's some stops that are built into the clutch center splined section that hit the disc part that will "get you home" if the rubber or spring damper goes out..

If it's been like that for a while, the stops can get worn bad, also the splines take a beating from the direct metal to metal contact at the clutch center stops.. If the splines are bad, there could be a worn edge all the way around the splined torque shaft, that would keep the clutch disc from coming all the way off without persuation..

May have to take the pressure plate bolts off somehow, to free the engine frome the torque shaft/stuck clutch disc.. After that you can get the clutch disc free with a gear puller.. If the torque shaft splines are damaged from the clutch disc/impact on the stops, you'd want to put in your spare torque shaft.

http://http://farm5.static.flickr.co...58628efaa8.jpg

http://http://farm5.static.flickr.co...4801f21d39.jpg

[IMG]http://http://farm5.static.flickr.com/4138/4804032607_30c56fae62.jpg[/IMG

Many thanks to all for your help.

Attached are links with photos detailing my problem

Corrected the image links for ya :) Should be (IMG)image link here(/IMG) except the square brackets, and one http:// infront of farm5....jpg and missing a close bracket on the last one.

http://farm5.static.flickr.com/4101/...58628efaa8.jpg
http://farm5.static.flickr.com/4119/...4801f21d39.jpg
http://farm5.static.flickr.com/4138/...30c56fae62.jpg

Carefully unbolt the speed and reference sensors, remove them, put in a safe place.. Remove the bell housing from the back of the engine, slide it back on the torque shaft up to the tube mount. Then unbolt the pressure plate.. Slide the bell housing/pressure plate/clutch disc and torque tube back into the torque tube housing, or remove the whole torque tube assembly/transmission.

It could just be the engine tilt angle, causing binding pressure on the splines, keeping it in place. For whatever reason it's stuck on there, the torque shaft should not have moved forward with the engine like that..

You will have to get at the rear of the torque shaft to fix the torque shaft to transaxle coupler, but for now try to get the pressure plate free and the engine out. Also, please put the oil filler cap back on, you don't want junk falling in there.

Yeah, engine out! Unbolted the bellhousing but it only could move back a inch. Removed all nine allen key bolts holding on the pressure plate and finally we had success. The thrust bearing is shattered into pieces and made a mess of the bellhousing. There was no way of the splined shaft coming out of the bellhousing.
I`ve put the engine crossmemeber back on and lowered the vechile back down three or four inches. Here comes the hard bit, that splined shaft does not want to go back into the torque tube. Any ideas?????

Some how you managed to break something dealing with the trans-axle to torque shaft trans-axle coupler
At this point you need to remove the trans-axle follow this procedure:
http://www.clarks-garage.com/pdf-manual/trans-03.pdf
If you do not understand something ask questions.

It may have just come loose from the coupler. You still need to get into the transaxle/torque shaft area to get the torque shaft to line back up with the transaxle coupler so you might as well inspect it for damage. Hope that the torque shaft wasn't worn at the clutch disc and hope that the torque shaft coupler didn't come off the transaxle splines, this could mean a dislodged "moved forward" torque shaft bearing.. Also, the splined shaft "torque shaft" has a relatively tight fit to the internal torque tube bearings, it might take a bit of pressure to slide it back through the bearing centers.

How did the splines look at the clutch disc side?