[Beeza]

We are attempting a clutch replacement and have come across a stopper at the moment.

The allen bolt that secures the sliding central shaft has been sheared off by a previous mechanic. They have attempted to remedy it by spot welding the remains of the bolt!

Our first option to remove this is to try and drill through the entire bolt and then tap and helicoil the casting. My question is this:

Is it possible to remove this shaft without further disassembly? We will need to remove the flywheel as we suspect a leaking oil seal, so with this removed, is there enough clearance to slide the input shaft forward to remove it without disconnecting the torque tube?

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[Johannvb]

Beeza,

The shaft slides back onto the torque tube, this gives you just enough room to get the flywheel out. Do a search here on the forum for EricK's DIY. This in combination with the factory manual will be very helpfull.

You could also try superglueing/ spot welding an allen key into the bolt. The bolt is not torqued very tightly so you should be able to remove it.

Good Luck!

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[flash]

that bolt is 59ft/lbs (80Nm), so i would make sure whatever you do is stout

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[Beeza]

I fear that these Dominican mechanics may have caused too much damage to this shaft. The spot weld is just too hard to drill out. I have managed to drill through the other end with a cobalt drill, but they are too short to go all the way through! I'm so close too there's probably only a couple of mm left to go, but I've run out of drill length on a 6.3mm cobalt drill. If I can't drill it all the way out without damaging the thread I might have to look at replacing the whole input shaft.

I have found a second hand one for $133. How easy is it to replace?

Will I have to remove the torque tube or will it come out forwards if the pilot bearing is removed?

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[Beeza]

Another thing I forgot to mention is that the allen head of this bolt has been completely sheared off. The remains of this bolt has been spot welded. This spot weld is very hard, not even my cobalt drills will touch it.

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