A-1 clutch pushrod stuck in pressure plate

Sep 04, 2003 0 Replies

Hello!



That's the problem that is keeping me from being able to separate the transmission from the engine on my 82 Rabbit, 4 speed. I cannot separate the engine from transmission because the pushrod apparently has either wore through the pressure plate and is now somehow stuck, or my bigger fear is that it passed through and actually welded to the pressure plate and the end of the pushrod is now too big to pull it back through the pressure plate. To make this repair even more interesting, the throwout bearing end of the pushrod has mushroomed itself from wearing up against the throwout bearing (it of course, fell apart). When trying to separate the transmission from engine, the pushrod jams against the throwout bearing end of the input shaft, telling me it is somehow still attached at the engine side.



BACKGROUND: My 82 Rabbit has a 4 speed transmission and a 85 GLI 1.8L engine. I have about 125,000 miles on the clutch that was installed new when the engine was replaced. A few months ago I experienced the "breakage of the clutch cable tube through the firewall syndrome" which allowed the cable to not work at all. I fixed that problem after researching on this group how to put a section of pipe through the firewall and use spacers. Cable seemed fine but no clutch pressure, so went to check for crack in splined shaft, and guess what? - throwout bearing was ruined, little ball bearings loose and all. No problem. Got new throwout bearing from local transmission shop (right part?...looked the same to me). Pushrod end looked fine, turned easy by finger pressure. Installed new throwout bearing, adjusted cable. Everything's fine - until - the other day, wife drives the car, says the car seems like it's running a bit rough, then clutch pedal goes to the floor. Take off end cover to inspect throwout bearing, and new bearing is shot, except now the end of the pushrod has mushroomed itself from wearing up against the throwout bearing and I can't even turn the pushrod let alone pull it out. Now, after jiggling the transmission around while trying to get the engine and transmissionseparated, the pushrod will at least turn. Pulling on the shaft with pliers, I get some back and forth, and I can hear it hitting metal at the engine side.



SOLUTIONS? I see 2 possible solutions, and want to get an idea on which would be best:



  1. Get a slide hammer with vice grip attachment and grab hold of the pushrod at the throwout bearing end and try to slide hammer the heck out of it from whatever it is stuck to/in on the engine side (the pressure plate, I presume). The biggest danger I see with this is possible damage to the input shaft (read=replacement transmission), but then again, jerking on the transmission to separate it from the engine is not a good thing either.
  2. Use a Dremel tool with carbide tip cutter to grind down throwout bearing end of the pushrod so that it will slide into input shaft. Drop engine down slightly and (hopefully) slide transmission off enough to get to pushrod to cut through it. I see a couple of dangers with this. First, I gotta be real careful with the Dremel in the confined space of the throwout bearing. Second, if the transmission won't slide over far enough to cut the pushrod, I am hosed.

I would appreciate any thoughts on these ideas, any new ones, or heck, even how through the sequence of events, led to this. What caused the pushrod to mushroom at the throwout bearing end? Of course, when I get the engine and transmission separated I will put in a new clutch, seals, etc...but that's kinda hard to do until I get them apart!!



Thanks in advance! Andrew



1982 Rabbit w/ 1.8 L

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