Just to give some more context for those that have yet to experience this problem.
1) Clutch slipping above 2000 rpm (surprised any bite at all when I saw how much oil in clutch housing and on clutch itself.
2) Evidence of drips at bottom of clutch housing.
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3) gearbox and cutch housing removed and inspection.
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The sound isn't the throw bearing or fork, it is the shaft knocking.
Last time I did the clutch I don't recall seeing this crack like mark and maybe I notice now as the oil covering makes it stand out ? So with the amount of oil I now don't know if it is down to a crack in the rear of the crown gear space ? There also looks like welding spatter, so then I start to suspect perhaps they are just casting marks ?
And notice there are other crack like lines around the housing which weren't so visible when I did clutch 4 years ago. Anyway I still don't know for sure and will have to hope it is just the seal and bearing and keep an eye on things once it boxed up again.
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5) Next step I wanted to see if could separate g/box from clutch housing and remove bearing and seal without taking gears out. Once separated and waggling apart slightly I found 2 x 13mm bolts which prevent it from coming free so removed those and then saw part of collapsed cage and at that point didn't know if a ball was missing as didn't know how many in the original bearing.
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6) It was at this point I thought best to strip down and clear out any bits from the diff and the g/box itself so removed the g/box end cover and quickly discovered if you decide to strip it would have been easier not to remove the already removed 2 x 13mm bolts because I could not remove the large 30mm pinion nuts. So I put the 2x13mm bolts back in, hooked up to the ball and fixed the g/box case back to the clutch housing with just a couple of bolts, it was then rigid enough to move selectors as shown which locked the shafts and then enable me to remove the 2 x 30mm nuts. Had to ratchet strap the g/box down to a table to get enough grip to loosen the big nuts.
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This pic was provided by my brother, to show position of selectors required to lock shafts, courtesy of the internet some place.
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7) After removing the large nuts, remove the bolt from the fork and then everything above the plate with the Alen bolts in will just pry off easy enough. Then remove the countersunk Alen bolts and that plate. This then reveals the end bearings on both shafts which are held in place by large circlip. Following the removal of those go back to step 5 and separate the g/box housing from clutch housing and remove the 2 x 13mm bolts inside. There is also one 13mm bolt on side of gearbox case which secures a small internal shaft off to the side. It is dead obvious and didn't take a pic. But the whole housing should just slide off the top now revealing both shafts, forks, gears etc.
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8) To remove the problem bearing I slightly tightened a 3 prong puller then arranged the balls in the race so that they lined up with the puller arms, I found this stopped the races from buckling as packed out where needed, IE where the pulling force was located.
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You can see from this last photo that it looks like the bearing has been in different positions on the shaft for a while so not actually sure where the true position should be but I did take a measurement of it last resting place as some kind of reference before I began to remove the bearing.
8) Measurement from end of input shaft to shoulder of inner race was 87.70mm
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9) And here is what is on the bearing, it's an SKF and is definitely the original as we have had the car from new (2010). I don't recognise the classification and even close up not certain what they say but will get the magnifying glass out and update if I can see them any better. Hope that is of some use to people. I have yet to decide which bearing I'm going to replace it with but leaning towards a roller bearing probably NJ204. Again will update what I go with. By the way I am replacing the oil seal too but I presume no photo's needed for that. But do have a photo of depth to seal so you have a good idea when it is seated. From shoulder of casting to metal outer ring is 14.80mm
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