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Oh, goody! Now I get to pull an engine, too!

Sarastro

Yoda
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Well, it finally happened. Got in the Sprite to go for a drive today, and the clutch went straight to the floor. I pushed Ruby Redcar back into the garage, cleaned up the puddle of DOT3 in the driveway, jacked 'er up, and took a look. The clutch lever was waaaaay back in an awkward position allowing the slave cylinder's piston to pop out of the cylinder. So, I guess that the pivot bolt has dropped out, or maybe the lever has broken--something like that.

I'll do an archive search for street wisdom on engine-pulling, but if anyone has any words of wisdom, I'd be more than happy to hear them. I haven't done this sort of thing for many years, and then it was with a TR4A, which is quite a bit different.
 
Tag your wires for "easy" reasembly. Order new gaskets ahead of time. You will probably have to order more as you go.
 
Steve, pulling the engine and trans is a piece of cake. Let me see if I can walk you through it.
Disconnect the battery.
Drain the oil from the trans, as it will run out the tailshaft when removing it. While underneath, remove the clutch slave cylinder and ground strap. Remove the two lower trans mount bolts from the bottom of the tunnel. If you have the exhaust support bracket from the bell housing to the pipe, remove it from the bell housing. Unhook the speedometer cable from the trans.
On a Bugeye, you can remove everything without pulling the bonnet. I prefer to remove it.
Drain the cooling system and remove the radiator and hoses. Don't forget the capillary tube for the temp gauge. Be very careful here. Don't manhandle the tube. Once removed, secure it out of the way. Disconnect the hose from the tube to the oil pressure gauge and plug it. Disconnect the wires from the coil to the distributor, and from the starter switch to the starter. Remove the alternator, or at least unhook the wires to it.

Remove the hoses from the heater valve to the heater, and the heater to the tube at the intake manifold.
Disconnect the hose from the supply side of the carburetors and plug the hose.
From inside the cockpit, remove the two upper trans mount bolts, located on either side of the tunnel, below and forward of the shifter. Remove the shift tower and shifter knob.
<span style="color: #FF0000">There is a spring loaded anti rattle plunger that can fall into the extension housing when removing the shift lever. There is a plug on the side of the shifter housing that retains the spring and plunger. Pull that and remove the spring and plunger prior to removing the shifter.</span>
Remove the three bolts holding the shifter cover to the top of the rear extension and pull the shifter.
Now, back to the engine bay.
You can either pull the manifolds from the head and tie them back out of the way, or disconnect the throttle and choke cables and the exhaust pipe. I tie mine out of the way after removing the manifolds.
Attach your engine hoist to the engine. I usually use a bell housing bolt on the uppper left corner, and a corresponding bolt to the right front corner. Ideally, you will have a tilt mechanism to use in conjunction with the hoist. It makes life a BUNCH simpler.
Put a very small bit of tension on the lift. Disconnect the motor mounts from the front engine plate. Remove the bolts holding the left motor mount to the chassis.
Slowly raise the engine. Once it clears the mounts, it will try to swing forward. Continue lifting, making sure it will clear the steering rack, etc. As it comes up, roll the lift away from the car until you're clear.
I'm doing this from memory, so if I've left anything out, I'm sure I'll be corrected quickly. Probably by Jack, who's had his out and back in three times this last week! /bcforum/images/%%GRAEMLIN_URL%%/grin.gif
As always, observe proper safety precautions, jack stands, wheel chocks, etc. If the front wheels of your engine lift won't go under the car, remove the cars front wheels and support it with stands under the front rails, near the firewall.
Hope this helps, and good luck!
Jeff
 
Jeff, thanks much for the detailed information. I can read the instructions in a shop manual, but it's invaluable to have input from people who have done it.

First task is to get a hoist--probably I'll get one of the foldable cranes from Harbor Freight; they seem to get good marks and are not too expensive. The job may have to wait until after Christmas, though, since I'm always pretty busy at the end of the year, and this one is no exception. But I'm already getting eaten alive with curiosity, wondering exactly what went wrong. I'll at least disconnect the slave cylinder and feel the clutch release lever a bit--that may give me a clue. For all I know, it could fall out in my hand...!
 
Steve, I've got one of the HF foldable hoists, and love the thing. I <u>did</u> replace all the provided Chinese bolts with grade 8 fasteners when I got it, and added a swivel hook for the chain. I use an Oberg tilt lift that I bought from Moss a few years ago, and it's given me great service through a lot of engine changes. I used to pull the engine on the Spit race car at <u>least</u> once a month.
If I think of anything I've missed in the procedure, I'll post an update. My guess is, that if I've missed anything, someone else will bring it to my attention! /bcforum/images/%%GRAEMLIN_URL%%/grin.gif
Jeff
 
I bet the bolt that the clutch release lever pivots on came loose, should have a self locking nut on it.
 
Steve -- I got my lift at Pep Boys, was a bit cheaper even than HF (was on sale at the time). I'm sure it's from the same Chinese factory. Works well, can't imagine being without it now.
 
Have been racking my brain Jeff, think you covered it all in great detail.
 
drooartz said:
Steve -- I got my lift at Pep Boys, was a bit cheaper even than HF (was on sale at the time). I'm sure it's from the same Chinese factory. Works well, can't imagine being without it now.

/bcforum/images/%%GRAEMLIN_URL%%/iagree.gif (Seems like they are on sale all the time /bcforum/images/%%GRAEMLIN_URL%%/grin.gif !! $119!) And would also recommend upgrading the fasteners as suggested above!! /bcforum/images/%%GRAEMLIN_URL%%/wink.gif

And I agree with Jack re: the lock-nut on the pivot bolt...at least a lockwasher!
 
Thanks for the suggestions. I'll look at the local PB sometime soon.

Got under the car today. The slave-cylinder piston was so far out it was cocked, and everything was jammed. I tapped the pin out of the fork in the clutch release lever and it all fell apart. As I feel it, it seems like there is nothing attached to the release lever--it just moves, rattles around, and goes quite far toward the rear of the car before contacting anything. It doesn't feel like there is a bearing attached to it. So, if I had to guess at this point, I'd say that the lever actually snapped. It felt like the pivot bolt was in place, though; I too suspected this. But, enough guessing; we'll know for sure when I get it apart. I'll keep y'all informed.

Well, pulling the engine is, after all, a rite of passage for Sprite owners. No reason why I should be spared it. Actually, I'm kinda looking forward to pulling it apart and seeing what's inside.

By the way, some of this information would do well in the Wiki...!
 
Steve, do you have a smoothcase or a ribcase tranny? Either way, I probably have a clutch release arm should you need one.
You could have had a throwout bearing disintegrate, too.
I've also seen the pressure pad on the clutch cover break off.
It'll have to wait until you get it out to be sure just what happened.
Jeff
 
Aye Jeff, I would suspect from Steves last post that the throwout bearing desinagrated or the fork broke or both.
 
Thanks--if I need it, I may well take you up on the offer. I really appreciate it. I have a ribcase transmission bolted to a stock 948 engine. I'm still not even sure what mix of clutch, slave cylinder, pushrod and so on this combination requires, but I'll find out what was installed by the guy who did the car's restoration.

Meanwhile, I gotta get all this $!#*@ work off my desk, and then I can get out into the garage and start having....fun!
 
I would lay odds that the bearing and or bearing casting have failed or become unattached from the fork! I'm not saying it hasn't happened (I'm sure someone will pipe in with one that HAS!) but I have never seen a fork break! I have seen forks bend quite a bit /bcforum/images/%%GRAEMLIN_URL%%/eek.gif !! Steve can you not take a peek through one of the plugs with a flashlight? Boy this is one where a proctoscope would be a really handy tool to have around! /bcforum/images/%%GRAEMLIN_URL%%/jester.gif
 
Well you know it is going to have to come out. So guessing dosn't help a lot. However, I too can not see the fork breaking but stranger things have happened.
 
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