so does anyone have any GOOD suggestions?

 

So what point are you at now, trying to pop off the TOB?

I have only done one clutch change but have scars to show the pain one can suffer doing the job with the limited two jackstands, a floor jack, a 2X4, several blocks of wood, two torque wrenches, other handtools, a fridge full of non domestic beer, and no help.

Getting it to unlatch is simple but takes about 30 minutes of wasted effort trying to force the sucker off first. It shouldn't take too much force but what makes it difficult is your pushing on the bearing in the same direction as the fork.

Try using a thick glove on your left hand or a rope to hold the fork lever. Get one of those LED headlamps so you can view inside, and go purchace good sized flat head screwdriver. It will pop off on one of those half discouraged efforts when your about to cry.

Just be prepared for the worst, most impossible part: getting the tranny back up in there - that really sucks, but with proper equipment would be a peice of cake. A few of my fingers are still inside the bell housing, luckily they grew back.

Seriously, get some help putting that tranny back in and on the engine - it really doesnt go but one way in.

Good luck

 

From the look of it you are prying on the wrong piece but, thats not the greatest photo to tell (although any photo would ook the same being how confined it is in there). Anyway, mae sur you are prying between the TOB and the spring mechanism on the clutch it self. the TOB, when its engaged after installation, is held in place by a ring attached to a piece that has (3) spring type pieces of metal behind that.

The TOB is held in by the ring around the piece I described above. If you let the TOB rest it its place without touching it you should be able to see the peice I am talking about attached to the clutch.

You need to push the flathead in between that piece and the TOB and turn the screwdriver 90 degrees. At this point you may need to hit the fork toward the tranny to get it to release.

This portion of the job is by far the biggest PITA, regardless of how many times you do this job. I've had some that release right away with no effort but, have had others that I'm screaming and cursing at to get to release!!!

If you don't have the service manual, check out www.ne-evos.net under the technical section, the manuals are posted there. That'll give you a good idea about what I'm referring to.

 

Here are a couple photos of first where to pry, then what it looks like when the collar is released. If the collar doesn't like to move toward the pressure plate with a screwdriver as shown, then move the clutch arm back and forth at the same time as you pry with the screwdriver/prybar. If done right it is an easy job and you shouldn't have to fight it. If done wrong, you can screw up the whole center section with one good "oops". I hope that helps.

 

I remember that painful TOB SOB quite well. And also remember playing with the new TOB and pressure plate to figure out exactly what to do once you get the tools up in there. It was a big help. Good pics ACTman. Make sure you get a pretty big flathead screwdriver. That collar needs to move about 1/2" to release, so at least a 1/2" wide screw driver should do.

 

ya thats exactly what I am doing I just cant seem to get it far enough to pop off, maybe i dont have a big enough screwdriver or something?

 

You need a decent sized flathead but, not something giant as it will only make it harder. You can try attaching a set of vice grips on the handle of the screwdriver to give you more leverage.

Just make sure you are placing the screwdriver in the correct spot. If you are behind the piece that holds the TOB into the clutch you'll have a very, very hard time release the TOB. In fact it most likely will not come off unless you break something. You need to be between the TOB and the spring to get the TOB to release.

After each attempt make sure you move the fork/TOB back and forth a few times (3-4) before trying again.