Gearbox nightmare any advice?

[Matt P]

Hi ,
I`ve finally bit the bullet and removed the engine / gearbox of my carrera to renew the clutch last night.
All was going well untill i tried to split the engine /box. Its a G50 box and it has had the conversion done on the shaft that holds the release bearing ( needle bearings in place of the brass bush) the problem i have is that when trying to remove the shaft with a slide hammer the 6mm bolt has sheered in the shaft !!! Because of the position of the shaft i can`t drill the bolt out now!!
Anyone had this happen or am i VERY unlucky?
Any advice very welcome
Thanks
Matt P

 

[Matt P]

Managed to get the bolt out but still can`t shift the shaft with a slide hammer! Was thinking about drilling out the needle bearing but does anyone know if this is the way to go ?
Thanks for any advice
Matt P

 

[dtunnicliffe]

Whoops,

Well reckon best bet for honest advice (and probably the most spot-on in UK) is give Neil Bainbridge a ring at BS Motorsport.

Dave

 

[Guest]

Does this post on Pelican parts help?

Removing clutch release shaft on G50

Look at the last response for an idea.

Cheers

Andy

 

[Matt P]

Thanks for your help but i did make up a puller and managed to tighten the bolt so much that i snapped the bolt!!
Might have to try a high tensile bolt and see if that does the trick.
Thanks again and i`ll post how i get on!
Matt P

 

[Guest]

Just out of interest, did you get the engine out at home? If so, what was the car up on? Was it on hydraulic ramps or normal home ramps? I've often wondered if it's possible to get the rear high enough to remove the engine using normal amateur home style ramps? Cheers

Kris

 

[Guest]

Its possible with a large trolley jack - search posts on Pelican for "engine drop" and you will get plenty of info. There may even be a technical article on Pelican.

 

[Guest]

Cheers Richard, I don't need to do it yet but mgiht do one day![]

 

[Matt P]

Hi Kristian ,
I managed to get mine out at home with a large (ish) trolly jack.
Before i lowered the car i got a measurement for you and it has to be jacked up to 22 inches ( taken from floor to where the drain plug is on the crank case).I had to remove the bumper too in order to get it out at this height but it doesn`t mention this in the Bently service manual. Hope this helps .

If anyone is interested how i got the shaft out of the box here goes,

I managed to unbolt the clutch through holes in the bell housing turning the engine over to get to each one, once these were all done you can seperate the engine and box.
You still have the pressure plate in the bell housing and to get this off you have to break the circlip that holds the release bearing to the pressure plate.
With the clutch completly removed you can now get to the shaft.
I tried everything to remove it but as a last resort i cut through the fork and then the shaft hammered out !
I had to buy a new fork,shaft and the bearings which came to just over £100 .
When i recieved the new one i found out why mine had siezed.The shaft and fork on the new items have a plastic collar between them whereas the old item had an aluminium shim between them that had corroded = tight fit!!!!
The moral of this story is , don`t panic all is possible.
Anyway while the motor was out i gave it a full service , new oil pipes and new torsion bar bush covers and can now enjoy driving it for the rest of the summer!!!