CGT gearbox / clutch problem - Page 8

BackintheFold · 27-10-22, 08:20 AM

>the extractor I bought really was a game changer,
Which type was it? The one with the rifled barrel ?
I've found thie type to be the best I've ever used:
https://www.amazon.co.uk/Impact-Remo...-2-spons&psc=1
(NB That's just an advert for the type-I'm not saying that item is the best or cheapest, it'sjust an example.)

84CoupeGT · 27-10-22, 09:23 AM

It was this one. Great value for money in my opinion, even if it only lasts 1 or 2 uses (still looks fine after one use though). It says impact stud extractor, but it is also for use with hand tools - I used it with a 1/2 inch ratchet with 3/8 adapter.

https://www.machinemart.co.uk/p/blue...d-extractor-1/

84CoupeGT · 28-11-22, 06:40 PM

Finally got some time on the car today, it's been up on stands/ramps on my parents driveway for a few months now, so I am determined to get it done asap!

I was waiting for a release shaft bushing to arrive from Latvia, which took a while. Unfortunately it is too small for the shaft, so I've had to reuse the old one. I've reassembled the clutch release mechanism with new guide sleeve and release bearing, and that all now looks good.

I spent quite a bit of time today trying to get the old pilot bearing out, but it just would not budge so I've left it in. I tried the packing with grease method multiple times and a slide hammer which I filed down the end of so it could fit behind the bearing, but it wasn't having any of it. After a few hours of lying on my back in 5 degrees I couldn't take any more so I'll just have to suck it up if the sodding thing explodes as soon as I drive it!!!

I did change the crankshaft seal though!

Remachined flywheel with new bolts went on and torqued to 75Nm, then new friction and pressure plates. Spent some time trying to ensure it was centralised with an alignment tool, I guess I'll find out tomorrow when I try to put the gearbox back on whether that was successful!!

Few pics including the battery tray area including where the clutch cable goes through the bulkhead. There was quite a bit of rust which I thought I'd sort out before installing the new cable. Fortunately it was all surface rust. Gearbox also been cleaned up a bit.

Colin Aitchison · 28-11-22, 06:48 PM

BackintheFold · 28-11-22, 08:27 PM

Impressive perseverance! It will be great when finished.

84CoupeGT · 30-11-22, 08:58 PM

Cheers!

Quick update on yesterday... The first attempt at getting the gearbox back on failed. Just couldn't get it on the final couple of inches despite raising/lowering and moving the box around on the jack. After a couple of hours I thought I must have not aligned the friction plate correctly so took the box back out (a right pain getting it off and back onto the jack under the car, not enough room to wheel it under the car with the box on top!). I could see from the grease marks on the smooth part of the input shaft that it had gone through the friction plate hub, and must have just been getting stuck on the pilot bearing.

I checked the alignment again by eye and with the tool (wrapped some electrical tape around the pilot bearing part for a tighter fit) and it seemed spot on. So (after some lunch and warming myself up inside), I decided to try again rather than take the pressure plate off to do the alignment again. This time I hoisted the engine higher at the front and had the gearbox at more of an angle. After a fair bit more jiggling, swearing and some bloodshed, the gearbox suddenly went on - woohoo!

I managed to get all the housing bolts back in, gearbox mount back on and re-torqued and the gear linkage back together, but after 8 or so hours outside I was done, and unfortunately had to leave it there as I had to head home in the morning

Ah well, progress was made and I've just got to reconnect the driveshafts, exhaust, starter and inner tie rods. So next time I'm there, a few more hours and should be ready for a test drive! Just hope it will be before Christmas

BackintheFold · 30-11-22, 10:39 PM

Excellent progress! Keep it up. Tax on 1 January?

SwallownAmazon · 30-11-22, 11:59 PM

Excellent - it's always a relief when the shaft goes in properly. When it's a bugger to get it in, it should be nice'n'tight and all lined up accurately.

K Simmonds · 01-12-22, 08:54 AM

Well done for perceiving and getting the box back in by yourself on the floor, it really not a fun job at all, that feeling when the input shaft decides to cooperate and slip in to the friction disc is great though.

I wouldn't worry too much about leaving the old pilot bearing in the crank as long as your attempts to remove it didn't damage it and I'm guessing it's well lubricated if you tried the grease compression method.

Putting the rest of the parts back together will seem easy compared to wrestling with the box, much more enjoyable,

84CoupeGT · 01-12-22, 04:58 PM

Quote:

Originally Posted by BackintheFold

Excellent progress! Keep it up. Tax on 1 January?

I'm hoping before then, but it does depend on getting a day or two with a reasonable weather forecast on a day I can pop back to work on the car. But yes, January at the latest!

27-10-22, 08:20 AM	#71
BackintheFold Senior Member Classic Audi Club Member Join Date: Feb 2019 Location: Near an MB ur Quattro Posts: 1,189	>the extractor I bought really was a game changer, Which type was it? The one with the rifled barrel ? I've found thie type to be the best I've ever used: https://www.amazon.co.uk/Impact-Remo...-2-spons&psc=1 (NB That's just an advert for the type-I'm not saying that item is the best or cheapest, it'sjust an example.) __________________ 2006 A3 (daily drive) 1987 MB ur

27-10-22, 09:23 AM	#72
84CoupeGT Grown up member Join Date: Nov 2020 Posts: 309	It was this one. Great value for money in my opinion, even if it only lasts 1 or 2 uses (still looks fine after one use though). It says impact stud extractor, but it is also for use with hand tools - I used it with a 1/2 inch ratchet with 3/8 adapter. https://www.machinemart.co.uk/p/blue...d-extractor-1/ Last edited by 84CoupeGT; 27-10-22 at 09:27 AM.

28-11-22, 06:48 PM	#74
Colin Aitchison Senior Member Classic Audi Club Member Join Date: Dec 2013 Location: Back home in Tillicoultry Posts: 1,315	Nice

28-11-22, 08:27 PM	#75
BackintheFold Senior Member Classic Audi Club Member Join Date: Feb 2019 Location: Near an MB ur Quattro Posts: 1,189	Impressive perseverance! It will be great when finished. __________________ 2006 A3 (daily drive) 1987 MB ur

30-11-22, 10:39 PM	#77
BackintheFold Senior Member Classic Audi Club Member Join Date: Feb 2019 Location: Near an MB ur Quattro Posts: 1,189	Excellent progress! Keep it up. Tax on 1 January? __________________ 2006 A3 (daily drive) 1987 MB ur

28-11-22, 06:40 PM	#73
84CoupeGT Grown up member Join Date: Nov 2020 Posts: 309	Finally got some time on the car today, it's been up on stands/ramps on my parents driveway for a few months now, so I am determined to get it done asap! I was waiting for a release shaft bushing to arrive from Latvia, which took a while. Unfortunately it is too small for the shaft, so I've had to reuse the old one. I've reassembled the clutch release mechanism with new guide sleeve and release bearing, and that all now looks good. I spent quite a bit of time today trying to get the old pilot bearing out, but it just would not budge so I've left it in. I tried the packing with grease method multiple times and a slide hammer which I filed down the end of so it could fit behind the bearing, but it wasn't having any of it. After a few hours of lying on my back in 5 degrees I couldn't take any more so I'll just have to suck it up if the sodding thing explodes as soon as I drive it!!! I did change the crankshaft seal though! Remachined flywheel with new bolts went on and torqued to 75Nm, then new friction and pressure plates. Spent some time trying to ensure it was centralised with an alignment tool, I guess I'll find out tomorrow when I try to put the gearbox back on whether that was successful!! Few pics including the battery tray area including where the clutch cable goes through the bulkhead. There was quite a bit of rust which I thought I'd sort out before installing the new cable. Fortunately it was all surface rust. Gearbox also been cleaned up a bit.

30-11-22, 08:58 PM	#76
84CoupeGT Grown up member Join Date: Nov 2020 Posts: 309	Cheers! Quick update on yesterday... The first attempt at getting the gearbox back on failed. Just couldn't get it on the final couple of inches despite raising/lowering and moving the box around on the jack. After a couple of hours I thought I must have not aligned the friction plate correctly so took the box back out (a right pain getting it off and back onto the jack under the car, not enough room to wheel it under the car with the box on top!). I could see from the grease marks on the smooth part of the input shaft that it had gone through the friction plate hub, and must have just been getting stuck on the pilot bearing. I checked the alignment again by eye and with the tool (wrapped some electrical tape around the pilot bearing part for a tighter fit) and it seemed spot on. So (after some lunch and warming myself up inside), I decided to try again rather than take the pressure plate off to do the alignment again. This time I hoisted the engine higher at the front and had the gearbox at more of an angle. After a fair bit more jiggling, swearing and some bloodshed, the gearbox suddenly went on - woohoo! I managed to get all the housing bolts back in, gearbox mount back on and re-torqued and the gear linkage back together, but after 8 or so hours outside I was done, and unfortunately had to leave it there as I had to head home in the morning Ah well, progress was made and I've just got to reconnect the driveshafts, exhaust, starter and inner tie rods. So next time I'm there, a few more hours and should be ready for a test drive! Just hope it will be before Christmas

30-11-22, 11:59 PM	#78
SwallownAmazon Grown up member Classic Audi Club Member Join Date: Jun 2017 Location: Tonbridge, Kent Posts: 511	Excellent - it's always a relief when the shaft goes in properly. When it's a bugger to get it in, it should be nice'n'tight and all lined up accurately.

01-12-22, 08:54 AM	#79
K Simmonds Senior Member Classic Audi Club Member Join Date: Dec 2009 Location: Mid Wales Posts: 1,060	Well done for perceiving and getting the box back in by yourself on the floor, it really not a fun job at all, that feeling when the input shaft decides to cooperate and slip in to the friction disc is great though. I wouldn't worry too much about leaving the old pilot bearing in the crank as long as your attempts to remove it didn't damage it and I'm guessing it's well lubricated if you tried the grease compression method. Putting the rest of the parts back together will seem easy compared to wrestling with the box, much more enjoyable, __________________ Still have my RS2 tuck up safe, also a 1992 C4 2.8 Avant quattro and a B3 quattro Saloon G60 conversion in progress.