The big clutch and flywheel adventure.

[tomstickland]

Right I've managed to get the input shaft out of the gearbox. Always the most worrying bit that.

However, I need some advice on how to get the drive shafts out of the gearbox. Previously I've attacked them with a hammer and chisel. But there must be a better way of doing it?

[Richard Bell]

Hi Tom,

Hammer and chisel is one way but be carefull as I once wrecked the diff in a box because the shafts would not come out and then we called Vauxhall and found that you can get a special tool and that works a treat If you hadn`t of started it I would have been more than happy to lend it to you!! I guess you will have got them out by now anyway.

Take care

Richard

[Trevor]

Take off the bottom ball joints and loosen the nuts on the inside of the wings.

Get a bit of steel and bend it at each end so it is a square "S" shape. One bit goes behind the inner CV joint between in and the gearbox and you hit the other end with a hammer. It should just pop out.

[cavvysri]

i just get a firm grip of the shaft and pull it like a slide hammer. always worked for me, but then again ive got a wee bit weight behind me...

[Animal]

i just pull em real hard, and they pop out!

[tomstickland]

Well I went out muttering about how I didn't believe you could just pull them out. I had a go and they did just pull out! Result.

I've just got the box off in the last 20 minutes. Things are looking good.

[DarrenH]

mother bitches, how come it took half a day and about 50 levering impelments to get the drive shaft outta my mates old cavalier ?

[cavvysri]

maybe you need to eat more and drink more beer.
BEEFCAKE!!:lol:

[Trevor]

Because it depends how worn the ring spring that hold it in is. I have seen them so tight they won't budge and so loose thay are falling out on there own. On the same car.......

[Gary]

I find the long one is always ok as there's a nice chamfer to drive a wedge into - the short one is a pain though as there's no easy way of getting leverage (as least on the F20 anyway) - this one can be forced out by undoing the diff ring which holds in the bearing - but that is a **** too.

anyone got any tips for the short one barring 'get the right tool' or 'yank on it' (ooer)

[tomstickland]

Well it's now 3am and I've finished. So thats 13 hours non stop grease monkeying. New clutch & release bearing, lightened flywheel.

I challenge anyone else to get a gearbox back on using two jacks and a piece of manky old rope.

Only thing that bugged me was that the input shaft was a bit reluctant to go back in. In the end I had to resort to a bit of action with the persuader. Hmm, not looking forwards to getting it back out next time.

Oh and with the lightened flywheel the clutch fixing bolts were sticking out the back frighteningly close to the engine. So I had to take all six bolts out and file them a bit shorter.

I've been out for a quick test. The good news is that it all works. No more sqealling from the release bearing. And it does feel faster. Sort of more keen to rev. Which is nice.