Cant remove roll pins

[dr.ian]

Hello, I am taking out the clutch...but I cannot get the roll pins out. How is this done? Also, I only see the large ones next to the transmission, where are the small ones? Thanks!

[kmaier]

The smaller roll pins are inside the larger ones, hiding from the hammer and punch. When you replace them, make sure you fill the hole up with silicone sealant first and orient the pins so the split is 90 degrees from gearbox axle shaft and the center roll pin is 180 degrees from the outer (roll pin).

Regards, KM
2000 V8

[FJ40]

There is a special punch from lotus. You can also use any punch but will risk damaging the pin race or mangling the pins, which will make it hard to get them out. Take your new pins ( a must ) to sears and by a punch that is almost as big or the same size as the new ones.

Dan

[NJGSX96]

You need to bang them out from the top. You need a variety of long punches to get the roll pins out successfully. I used a real skinny punch to get the center pin knocked out a little and then went to a larger punch to finish the job, knocking out both pins. It can be frustrating at first but take your time and you'll get them out.

[kmaier]

Also, here are some p/n for the Lotus sourced tools:

T000T0678 - Roll Pin Punch Set
T000T0679 - Castellated Wrench
T000T0680 - Differential Nut Spanner
T000T0681 - Output Shaft Seal Replacer
T000T0682 - Gearbox Support Plate
T000T0654F - Clutch Alignment Tool I4
T000T1402 - Clutch Alignment Tool V8

Hope this helps.

Regards, KM
2000 V8

[autocross7]

I have only seen the roll pins removed... I opted for an 88' with a C5 gear box. On face value I think the C5 is a bit easier to work with. But... a mechanic friend of mine pretty much said the same as the above when I brought the subject up. Take your time and do not get in a hurry. He also recommends using a rubber hammer vs a steel one when drifting the pins. (Drifting I suppose is a relative term as this requires some pounding)


Good luck and Drive topless!!!
Cameron

[NJGSX96]

So how did it go? get those pins out?