<VV> my throwout shaft is cracked

[N. Joseph Potts]

Replace the shaft. However long the crack is, it will grow longer until you
have a messy leak that will attack your clutch function. Do not use an NOS
or used shaft - get an upgraded replacement from a vendor (it will provide
for two input-shaft seals).
    You're looking at a ticklish reassembly job on that diff that will
require SOME special tools borrowed, bought, or contrived. Consider
consulting your Shop Manual (in detail).
     I think I would recommend purchasing a rebuilt diff from a vendor. I
recall they sell these. I HAVE rebuilt my diff two or three times (different
problem each time), and I have accidentally found problems in it that were
over and above whatever I was going in to fix. I believe my first reassembly
or two may not have been adjusted quite right (by me), and these MAY have
contributed to the later failures. These are eternal mysteries - I will
never know, will always have some estimate of the possibilities, that
actually changes as time goes by and I hear more things about this area of
black magic.
     IF you decide to rebuild yourself, repeat your question about what
should be replaced, and I will provide a prioritized list. Depending on how
aggressively you go into the list, you certainly can get into some money
(hundreds, not thousands). Do you have a dial indicator? Know what one is?
Know how to use it? It may be the key tool used in a rebuild, and it is NOT
one of the "special tools" I referred to.

Joe Potts
Miami, Florida USA
1966 Corsa coupe 140hp 4-speed with A/C

-----Original Message-----
From: virtualvairs-bounces at corvair.org
[mailto:virtualvairs-bounces at corvair.org]On Behalf Of John McMahon
Sent: Thursday, March 31, 2005 9:08 AM
To: Virtual Vairs
Subject: <VV> my throwout shaft is cracked

Actually, the throwout shaft on my differential IS cracked, and I've been
toying with whether or not to replace it.  The crack (at least the only
*visible* crack) starts at the front and goes back about an inch.  I filed
the shaft down so that the bearing slides freely, and since the crack does
not extend back to differential, I was thinking maybe it wouldn't leak.
What say ye?

And exactly how long would it take a mechanically inclined Corvair newbie
like me to take apart the differential and replace the shaft?  And what
items always or usually have to be replaced while one is in there?

Thanks,

John McMahon
1965 Monza coupe

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