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TR2/3/3A Odd Clutch Failure...Clutch crosshaft bushing goes for a walk!

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K

karls59tr

Obi Wan
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The clutch stopped working last summer and I just got around to pulling the gearbox to check out why the shaft would only move an inch either way. I figured the notorious taper pin had broken but years ago I had done the 3/8 bolt fix so I thought the shaft may have actually broke! It turned out that one of the crosshaft bushings had come loose and worked it's way out of the housing and along the shaft. This caused just enough play (along with a worn release bearing) that when the clutch was depressed the release bearing sleeve slipped off the input shaft and jammed so could not return. There was a lot of grease on the shaft ends so I may have been overzealous with grease....maybe even forced the bushing out with grease??? Anyone heard of this? I have a spare shaft that is in good shape...old shaft has significant wear. One of the holes in the bellhousing where the bushing sits is somewhat wallowed out on the inner side from the shaft banging against it. I wonder if I built up that area with Kwik Steel or an epoxy mix and then fitted a new bushing I could solve that problem? Was there a post somewhere on using two bushings on each side instead of one? On a positive note the clutch disc and pressure plate are still in great shape. Any ideas or comments?
 
I wouldn't trust epoxy with a repair like that. Find a machinist that can ream the hole back to round and fit an oversize bushing (or bush it back to the original diameter).

Seriously doubt you forced the bushing out with grease as it is open at both ends and should be a very tight fit. I'm guessing instead that someone damaged the hole installing the bushing (or a previous one).
 
Too much pressure on that small area to use epoxy for building up surface. Maybe some to hold the bushing in place. A machine shop can easily drill it out a bit and fab a bushing for it. Might as well do both sides while your there.

Marv
 
Richard Good sells a nifty kit that lets you install roller bearings - might be overkill but it does look nice.
 
Richard Good is owner of Goodparts - mainly TR6 performance oriented. Here's a link to his kit:
https://www.goodparts.com/shop/index.php?productID=390

Pricey and potential overkill but it shows an alternative to those pressed in bushes.

ps. if you actually did consider the kit it would be best to contact Richard, since this kit is set up for 4A-6 clutches, not TR3-4. The needle bearings would work though, so perhaps he would sell just that part of the setup.
 
Another possibility might be Herman van den Akker's "Hydraulic throw out bearing". Although he normally sells it as part of the 5-speed conversion kit, I believe it will fit and work with the stock early gearbox (double-check with Herman, though). It totally eliminates the shaft (and that darn taper pin).
https://www.hvdaconversions.com/accessories.html
 
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