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mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Well I think I've figured out the problem. When I did my TT rebuild last week I had to drive out the drive shaft from the TT and then the carriers. I ended up using a 7' piece of steel rebar and drove it out. When I did this, I think I may of screwed up the end of the drive shaft a little and now it's locked in the pilot bearing. So basically it's not spinning in the bearing and it spins the entire time the flywheel is moving. Which would make sense why it's grinding when I try to put it into gear. Right?

I'm ordering a new pilot bearing tomorrow but before I do, take a look at this one that came with a clutch kit I got a while ago. I didn't use it because it wasn't like the one that came out. Is this one ok to use? It seems much weaker than the other kind so that's why I didn't go with it. Once I'm able to get the drive shaft pulled, I'm gonna smooth out anything that needs it and then reinstall everything and then I should be good to go.

_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

Doodle · Posted: Mon Jun 08, 2009 9:25 am Post subject:

Something else to check since you had all the pieces out. Assuming you have the 4 speed gearbox. The two adjustments in the Haynes, page 168, Figs. 7.10 and 7.11 are rather crucial to proper gear engagement. I know this from personal experience. Might be worth a look and is fairly simple to do compared to removing everything again.
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Doodle
Pre 77.5 Mars Red

924RACR · Posted: Mon Jun 08, 2009 11:01 am Post subject:

That's the kind of pilot bearing we're using in Marsh's car...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

well you said the car did good this weekend so I guess it would be ok for me too then. How far did you press it in? And what did you use to press it? Socket? I'm still havin a hell of a time gettin the TT/tranny to slide back. I guess the shaft IS sticking to the bearing. I may have to hook a strap to the tranny and to the Taurus and give her a yank!

_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

924RACR · Posted: Mon Jun 08, 2009 10:07 pm Post subject:

Chris ended up having to create a whole new carrier for that bearing, as his was destroyed; don't know what he pressed it in with, might've used a press (since we were in his shop!)...
_________________
Vaughan Scott
Webmeister
'79 924 #77 SCCA H Prod racecar
'82 931 Plat. Silver
#25 Hidari Firefly P2 sports prototype

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Ok well after lots of swear words I got the rear suspension, tranny, and TT removed...AGAIN.

After inspection of the driveshaft I found that when I did my TT rebuild, I must have "mushroomed" the end of the shaft where it goes into the bearing and it locked itself in there. So now the bearing is stuck. I have the flywheel removed and when I use a bolt to try to back out the bearing, it just spins. The threads must be messed up.

So...how do I get this damn thing out? Is there a bearing puller tool of some sort out there? Or should I put the bolt back in the bearing and use a pry bar and pull it like you would if pulling a nail from wood?

Also, if you see the pic of the bearing (in the above response) that I have now, the ID is bigger than the OD of the driveshaft. It can't be the right size??? Or should the driveshaft be loose in there?
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

!tom · Posted: Thu Jun 11, 2009 9:53 am Post subject:

The pilot shaft bearing should be the same size as the shaft so that it runs true. Otherwise I'd expect some nasty chattering of your clutch.

What spins when you try to remove the bearing with the bolt? My understanding is that you run the bolt in tight, and it pulls the bearing out if you've used some penetrating oil first. If the bolt spins, I'd expect that means the threads have been stripped, which would mean you can't pull it like a nail like you suggested.

One option is to cut the darned thing out.
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78 924 NA
5-lug

Mike924 · Joined: 12 Aug 2004 Posts: 2601 Location: IoW UK

Mike,

do a search on Rich H's posts. He came up with a novel way of removing the pilot bearing, IIRC, and also the part number of an industrial equivalent at a fraction of the price.
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1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

Mike924 · Joined: 12 Aug 2004 Posts: 2601 Location: IoW UK

Actually, Rich's method wasn't that novel after all...

http://www.924board.org/viewtopic.php?t=22764

http://www.924board.org/viewtopic.php?t=22834

But there'e useful information there anyhow.
_________________
1985 Porsche 924 'Lux', Kalahari Beige (my ex)
1993 Porsche 968 Coupe, Midnight Blue, 6 spd

'There is no substitute for a little grease under your fingernails.' - Chrenan, 924board.org

Nobbi · Joined: 24 Aug 2006 Posts: 1398 Location: Germany

Iirc the part in your hands is the oldstyle 2 part setup (Sealring and bearing)which is not longer available. The new pilot bearing should be longer and just one piece....
The order number is 047105169 A

Make sure when you install the tt that the engine is facing down a bit at the clutch side and you dont give the tt a chance to "hang" into the bearing at any time. It will bend your shaft or kill your bearing.

think positive, the car will pay back....

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500.000 km with fun.....and new toy:Porsche 944 S2 Cabriolet.Other car Daimler c-class cabby,brandnew..Plus : DEUTZ 4005 tractor Built 1967

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Well I'm still stuck, literally. The bearing that's in there now isn't like the one in the picture. It is the one that is longer and all one piece. My Photobucket isn't downloading right so I can't show you a pic of what it looks like now. But it's the much thicker style. I don't think cutting it or chiseling it out is an option. I have the flywheel off and can grip the bearing just fine with a pair of vise-grips but the crank turns with it. And if I put the flywheel back on I can only just barely get a grip on it. I'm thinking of trying a larger diameter bolt???
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Ok I got my photobucket to work. Here's a pic of what I have now..

_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

Ok I'm really starting to get frustrated. I have a new pilot bearing coming and it will be here on Thurs but I still can't get the damn old one out.

After talking with Paul (after a bad hockey game..) he said to try filling the bearing with grease and then pushing my clutch alignment tool in to push it out. Sounded good in theory but all it did was make a huge greasy mess. I've read all kinds of threads on this last night but nothing seems to be working. Since I have the thicker style (not sure if it's a type 1 or 2) cutting it out doesn't seem like an option. I'm going to run to the store and try to get a bigger thread bolt and see if I can make that work. Other than that..I got nothing.

Any other ideas??? Really makes me mad that I've done all this work and this dumbass thing is holding me up from finishing!!
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)

mgatlag · Joined: 02 Aug 2007 Posts: 647 Location: Avon, IN

SUCCESS!!!!

I ended up going to the local auto parts store and getting their re-thread kit and basically just re-threading the carrier using a little larger of a size and whaala! She came right out. Now I just have to unfortunately wait til Thurs for my new bearing to come in and then I can reassemble everythying and get back on the road.
_________________
Michael
'77 1/2 924 N/A- 5 speed Audi box
'04 Ford Taurus - gone!!
'92 Jeep Cherokee Laredo - gone!!

Porsche... better than tea with Miss McGill
(Slap Shot)