Date:         Sat, 9 Apr 2005 03:13:43 -0400
Reply-To:     Jonathan Farrugia <jfarrugi@UMICH.EDU>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jonathan Farrugia <jfarrugi@UMICH.EDU>
Subject:      Re: Help removing clutch lever
Comments: To: Shawn Wright <swright@ZUIKO.SLS.BC.CA>
In-Reply-To:  <42557D3C.20855.32E027A7@swright.zuiko.sls.bc.ca>
Content-Type: TEXT/PLAIN; charset=US-ASCII; format=flowed

Shawn

i'm probably a little late in responding to this but here is my input.  my
solution was heat vibration and oil.  i made a heat shield that went
behind the clutch lever and used a torch to heat it up good and hot.
doing this will melt the plastic bushing parts even with the heat shield.
after heating, vibrate the area with a hammer and punch if needed then
cool it all down with penetrating oil.  then more vibration, after that
attempt to pry the lever off.  if it doesn't come off repeat the process
until it does.  when you get it off don't forget to anti seize it when
you put it back together.

i did all of this on the bench with the tranny out so that tells which way
i prefer to pull my trannies :).

jonathan

On Thu, 7 Apr 2005, Shawn Wright wrote:

> I can't get the &#*$(# clutch lever off the clutch fork rod! I need to get this
> apart so I can replace the broken up plastic sleeve on the rod. I've let is
> soak overnight with PB Blaster, and bashed it as hard as I dare, but there
> seems no way to hold this thing still while bashing it without destroying the
> bellhousing! This is a diesel bellhousing, otherwise I probably would have
> smashed it to bits by now in frustration. Should I try heat? Cut the damn
> thing off?
> Any suggestions appreciated before I ruin the bellhousing!
>
> Shawn Wright
> http://zuiko.sls.bc.ca/~swright
> '85 Jetta D
> '88 Westy 2.1L, soon to be 1.6TD 5 speed
> '82 Diesel Westy
>
>
>