Clutch lever pain

sven · Jedi Guardian Joined: 27 Dec 2006 Posts: 814

The bellhousing I'm going to use for my TDi is badly corroded and I have to make new parts to replace the pieces that fell off(!)...
I had to get the clutch shaft out, the lever was really stuck and in the end I had to cut the shaft in pieces to get it out. I have to use a combination on the new setup, the lever and the mount for the slave cylinder differs between the diesel and the gas bellhousing. I think the shaft is the same but...
Does anyone know if the shaft is different as well?

Unfortunately (or should I say as usual...) the same story goes on the gas bellhousing - the lever is stuck and I have to cut somewhere to get it off. My plan is to cut the gas lever itsellf so it can be expanded and then knock it off the shaft. Before everything is reassembled again I might customize the diesel lever as well with a cut and then add a bolt to tighten it around the shaft. Not needed now maybe, but it'll be much easier to remove in the future.

sven · Jedi Guardian Joined: 27 Dec 2006 Posts: 814

I'll answer myself. Happy

According to Just Kampers website it's the same shaft.

If you plan a diesel project, make sure that the bellhousing and the clutch parts are in a decent condition. The lever arm and the slave cylinder mount is different from the gas version, be careful with them...

ElusiveStranger · Posted: Fri Jun 24, 2011 11:21 pm Post subject:

If it's any consolation, getting the f##king arm off my shaft required:
1/ Oxy acetylene
2/ Brute force
3/ Bucket of water
4/ Sponge, for quench (for #3)
5/ Bigger puller
6/ Bigger hammer
7/ Swearing
8/ Prayers
9/ Paul_f

Followed by a set of needle files putting the splines back in order
Absolute cnut of a job - never want to do that bit again. Wiring loom was a POP in comparison.
_________________
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Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin

Bugger, missed out on "Live fast, die young"

sven · Jedi Guardian Joined: 27 Dec 2006 Posts: 814

Ha ha! About the same then I think. Happy

sven · Jedi Guardian Joined: 27 Dec 2006 Posts: 814

I'll add more info in my build thread.

ElusiveStranger · Posted: Sun Jun 26, 2011 1:40 am Post subject:

JB Weld it - it'll be fine

Oh. I missed off the bigger vice, swearing, bigger bench, bigger pullers, swearing, Band-aids, swearing
_________________
The advice you receive on here is worth the paper it's written on.
Your experiences are worth shed loads to others, including the f'ups - live and learn.
Wouldn't YOU rather learn by someone else's mistakes? So would they.

'78 Bay, 2 litre 091 box, EJ20 NA & the ashtray's on the 'right' side.
I don't lean forward for hills any more Grin

Bugger, missed out on "Live fast, die young"

sven · Jedi Guardian Joined: 27 Dec 2006 Posts: 814

I ended up with this. It's fixed and aligned with fibre reinforced filler and then locked with two screws. Crazy sturdy. Happy

There's a new bushing inside but the sealings are from the old bellhousing.
Hopefully the paint will stop the galvanic corrosion a little bit.