This is part two of the clutch replacement. Very Long. Delete now if no
interest. . .
-----------------------------------------------------
I took a 30-minute rest and made sure from atop and underneath all bolts were
free. Now with the 2X4 under the transmission I slowly rotated the trans. It
took a few CAREFUL pry’s on my rolling crowbar to ease the Trans from the
engine. Like I said I had comfortable room underneath so I took my time. When
the trans was apart about one inch from the engine I manually slide it back
further. With both hands on the trans. I slowly rotated it and slide it back
about another 2 inches. About 4 inches was as far as I could get it to go
back. The problem was that the top cover of the gear shifter was hitting the
sidewall of the Trans tunnel and I was about 1/4 to 1/2 inch short of space to
be able to rotate it fully to slide it back. The problem was that I could not
get to the bolts to unscrew it. ARGGG. With several very forceful turns I
tried to get the Trans to roll past the sticking point, but it just wouldn't
roll much further than about a 1/4 transmission turn. And to make matters
worse at the front of the Trans where the round egg like shape is, prevented me
from being able to force it back without rolling it at least the one-quarter
turn. To say the fit is tight is an understatement. All I needed was about
1/2 inch more space on the passenger side of the transmission tunnel and I
would be home free! AARRRGGGG!!!
After about 40 minutes of force, finesse, grease, and several reviews of books
and drawings, I decided to get the clutch plate out and think about this
further. It was somewhere about 4:00 at this point. I follow procedure to
unbolt the clutch plate and it released. At this point I had the jack with the
2X4 lumber under the back 1/3 of the trans. THANKFULLY. When I released the
last bolt of the clutch plate, the Trans dropped. I guess the center rod was
still in the clutch plate. I was able to gain control of the Trans with one
hand while holding on to the clutch plate with the other. No body/finger
damage, I'm just glad that I decided to wear thin gardening gloves and this
provided the grip I needed. I was able to get the jack directly under the
center of the Trans and remove all the clutch parts. I then decided not to
wrestle the Trans and let it rest down on the ground. I did not want to pull
it out completely so I just let it rest where it was.
MANY MANY Surprises were to come. I found that the release bearing was not just
bad, it was in about 20-30 small and large pieces with distorted metal and
spring parts, YES spring parts from the clutch disk laying in a goop of metal
flakes and caked oil (or something like it)? I guess it needed to be
replaced!!!
It took me another 30 minutes or so to clean up the inside of the Trans tunnel.
I also have a problem with the clutch level. Some of the metal is worn down
at the top. What I mean is that where the release bearing sits in the clutch
lever, at the top of the curve there is rubbed out metal. Like it was sitting
on a grindstone.
This is why I am asking if anyone has a good used clutch lever they want to
part with.
At about 5:30 or 6:00 I decided to put the new clutch plate and clutch disk on.
It went on without many hassles. The clutch alignment tool now goes in and out
without friction so I just need to torque it down (I guess 100 pounds). I
could not find any specs??
At 6:30 I stopped and spend the next hour cleaning up.
SO WHERE AM I NOW:
Now the transmission sits on the floor. I will probably take it out all the
way, grab a mallet and pound 1/2 inch well on the inside where I was having
problems earlier so I can slip it back in and all the way back to clear the
center rod when I refit the transmission to the engine. If I cannot find a
good used clutch lever I will use JB weld and reform the end of the top. About
1/4 of an inch was ground out on the top front holder. From that point, it
will probably take two people to refit the transmission, but I think that if
needed, this could be done with one person. CHRIS IF YOU’RE READING THIS FAR,
I COULD REALLY USE YOUR HELP ON THIS PART. And then of course rebolt everything
back.
I figure I have about another two-three hours max before all is said and done.
SO, can it be done from underneath, YES. With just ONE PERSON!
I am surprised my hands are not as sore nor my body more bruised given the
workout, but using the proper tools, taking it slowly and relying on jacks
really made this workable with one-person. If I did not have the problem with
the clutch lever it could be a one-day job. For about 6 hours work, and for
the first time EVER, I think this is a pretty good job so far.
Stay tuned . . .
James Porco
Dublin, Ohio
|