It gets worse .....

[zhastaph]

Thanks for all the advise so far with regards my clutch.

I'd decided in the end to pull the gearbox completely then make a decision as to where to go from there, but kinda expecting that a new clutch is most likely the order of the day.


However, I cant get the gearbox off

She's completely free and is far enough from the engine that she's off her dowels (about 1/3rd of an inch) and will rotate slightly, but no matter what we try she will not come an inch further. We've even tried 2 of us pulling with 2 x 5ft bits of wood prised between the box and the space frame.


Firstly, I'm not missing anything am I? From what I can tell she is only held in by the input shaft and nothing else. I'm gonna try screwing the box back in and pulling it again to see if that will help and keep repeating that till it budges.

Anyone else have any suggestions?

Heartbroken Zhastaph

[Paula&Marcus]

Hi,
Looks like you have a seized-spline vs. friction-discs problem.
Try squirting some penetrating oil inside and try again. Please dont use too much force.

Are you far enough away to get acess to the bolts that hold the pressure plate to the flywheel ?

Cheers
Marcus (www.PUKesprit.de)

[zhastaph]

I thought about squirting some penetrating oil in there, but I cant see any of the spline even through the hole where the clutch fork lies. I'm a bit reservant about just spraying it madly in there because at least at the mo I still have the option of putting it back together.

I'm not far enough to access the bolts from outside of the gearbox, I can only just see the ring gear in the gap that I have from the engine. But it may be accessible from where the clutch fork is, certainly sounds like an avenue worth exploring.


>> Edited by zhastaph on Sunday 13th March 19:26

[Dr.Hess]

Kinda sounds like you found your problem.

Dr.Hess

[Esprit2]

zhastaph said:

However, I cant get the gearbox off She's completely free and is far enough from the engine that she's off her dowels (about 1/3rd of an inch) and will rotate slightly, but no matter what we try she will not come an inch further.

Have you disconnected the fork from the release bearing? The V8 clutch uses a pull motion on the bearing. To facilitate that, the bearing is clipped to the clutch diaphragm spring and the fork is clipped to the bearing. Before removing the transmission the fork must be unhooked from the pivot ball so the fork fingers can be slid out of engagement with the bearing.

If you have already done that and it's still stuck, then you're probably in for a fight with the splines as Marcus mentioned.

You don't need to fight it all the way off while in the car. Just far enough to permit access to the clutch mounting bolts... turns things as required. Then remove the clutch with the transaxle and finish the battle on the floor.

Best of luck,
Tim Engel
Lotus Owners Oftha North

[kmaier]

Esprit2 said:

zhastaph said: However, I cant get the gearbox off She's completely free and is far enough from the engine that she's off her dowels (about 1/3rd of an inch) and will rotate slightly, but no matter what we try she will not come an inch further. Have you disconnected the fork from the release bearing? The V8 clutch uses a pull motion on the bearing. To facilitate that, the bearing is clipped to the clutch diaphragm spring and the fork is clipped to the bearing. Before removing the transmission the fork must be unhooked from the pivot ball so the fork fingers can be slid out of engagement with the bearing. If you have already done that and it's still stuck, then you're probably in for a fight with the splines as Marcus mentioned. You don't need to fight it all the way off while in the car. Just far enough to permit access to the clutch mounting bolts... turns things as required. Then remove the clutch with the transaxle and finish the battle on the floor. Best of luck, Tim Engel Lotus Owners Oftha North

First, as Tim mentioed... you MUST disengage the release fork. Just remove the clutch slave cylinder assembly from the bell-housing (3 bolts) and you'll be able to look down and see the clutch pack the release arm will be sticking up... grab it and pull directly out... it will unclip with about an inch of travel.

Next, wiggle the gearbox assembly left/right then up/down to crack the rust loose while pulling the gearbox away from the motor. It took me about 10 minutes to work it loose. If you plan on reusing he clutch I don't recommend spraying any penetrating oil down there.

Regards, KM
2000 V8