I am R & R'ing my clutch on the Evo Viii

The online shop manual talks about pulling the "output shaft" - a shaft that appears to go through the transaxel - into the transfer case - its a shaft that the driver's side halff shaft snaps onto

The manual says you need some special slide hammer to pull the shaft out of the trans

My question is if anyone else has done the clutch job and IF you have to pull thats shaft out becuase I have been wacking away fairly good at that shaft with a tool i made up and it dosn;t seem to want to come out

 

Thanks for all the help - fellow evo owners !

I wound up getting a el cheapo dent puller - then I tapped on some 8 mm threads to the end

Presto bango and out teh shaft came

Now I have the transfer cash half way out and am waiting to round up some crew to help me to move the enging down and forward enough to drop out the transfer case
My only consolation in all of this is at least this car is almost new and very clean

I would hate doing this nightmare job on an old rusty and dirty heap thats been in the snow for s few years

 

clutch finally went eh?

or are you just upgrading?

 

You're on unknown ground, Al. I sat and watched Friday as an experienced DSM AWD mechanic try for 4 hours to remove the transfer case on my car, no dice. That despite repeated calls to consult with the local Mitsu dealer mechanics. hopefully he will figure it out on Monday, and likely they regret giving me a set price rather than hourly rate.

So take pics, write up a good how-to, as lots of us are going to need it.

 

We got it out after doing thye following :

1 - made a custom slide hammer "output shaft" remover - I took an off the shelf dent puller and grafted some 8 mm threads onto the end of it with a die - - with that the shaft poped right out of the driver's side of the tranny

2 - there are a total of 6 bolts holding the tranfer case - the last one is kind of hiding up in there

3 - you have to remove ALL the motor mounts and move the engine all the way up to the front as far as you can and also lower the front of the motor down as far as you can

Once you do that - the transfer case can be slid, twisted and contorted up over the power steering lines and out through the small gap between the sub-frame and the engine

The real fun I think will be putting it back into place - the splines are very strange and it can only go in one way

A flat rate deal on this job is a great deal for the customer

Its a long job and not one that is a lot of fun

The only good news so far - for those who are sticking with the stock set up - - we have a very light weight stock flywheel

 

wow, and i thought this was gonna be hard..... ....man...

-Shahul

 

Why didn't you just drop that sub-frame? From the looks of it, that would be much easier.. But as we all have heard, looks can be decieving...!!

 

The shafts into the transaxle were the issue. The mechanic was used to older DSMs and Subies, where the axles have a female splined end to go over the output shafts, and the shafts stay in the tranny when removing. Once he figured it out he used a puller to yank them out, and it was cake from that point.

Love the Exedy single disk so far. Grabs like heck, but can still slip it for high RPM launches. Actually has a bit lighter pedal feel than stock too.

 

how much and where for the exedy clutch?

 

Got it over at Z-1 Performance for about a $100 less than what they list on the site. Call Adam up, he worked hard to make sure I got the part quick.

 

thanks you answered my question, I will go and find a puller to get that sucker out.

 

Great innovation on the shaft removal tool. I've been ramping up to do a clutch job myself, and you just solved my biggest concern. Nice work.

As others have said, removal of the sub frame seems to be the way to go from others who have tackled this job. My be a bit more work, but I think it would be worth it to not have to move the motor around so much and risk busting PS lines or worse. Keep us updated on any more issues you may run into.