Trans trouble

[Avenger]

Okay, my friend has a 92 Shadow we've been trying to get back on the road. It's a 523 trans, and the trans itself had been pulled back in the spring for a new clutch and pressure plate. When he pulled it out, it was COVERED in clutch material and oil, so he pressure-washed the entire inside of the bell-housing. And then left it sit outside. This was less than ideal....Because everything rusted or oxidized.
Well, the clutch release shaft.....doesn't release. At all. It's bound up somehow, if you hit the arm with a hammer (I know, I know) it'll move a tiny bit. Obviously, it isn't supposed to be like this, and the shaft needs to come out to be fixed. But, even with the retainer clip out, it does NOT move. I was actually LIFTING the transmission by the release shaft and it wasn't coming out. It has been WD'd, PB'd, and even Kroil'd, and it isn't coming loose.

Did I miss something in the disassembly process? My FSM shows two clips, one on the outside that keeps the arm on the shaft, and one inside the bellhousing that keeps the whole thing from falling out. I pulled the inside one, and the shaft should be coming out....but it isn't. HELP!

[Avenger]

C'mon, anyone got anything? Somebody has to have done this before! If we can't figure this thing out, he's just going to end up junking the car, since he doesn't want to pay for another trans from the yard.

[NAJ]

I am not a trans expert and have never had one apart but I have been working on cars professionally for 32 years so I will try to provide some service info for you, just need you to point out in the images what you are referring to by the "Clutch Release Shaft".
Are you referring to the clutch fork, input shaft and retainer?

[Avenger]

It's the shaft that goes from the clutch arm (that the clutch cable pulls on) to the clutch release fork (that pushes the throwout bearing against the pressure plate fingers). It's not shown in your pictures, since "technically" it is part of the clutch assembly, not the transmission. I had the same trouble finding info in the FSM, had to look under the clutch section.

I'm thinking that the bushings it rides in are full of rust, and that it what is jamming it up. But it still isn't coming out!

[NAJ]

Found the shaft you are referring to and if it will not come out I would suggest installing the release lever and use heat on the bushing end and tap on the release lever to break it loose.
Propane may not get hot enough, I recommend MAPP gas.
Just be sure all other components that may be damaged from heat are removed and clean all flammable liquids from the bellhousing before heating.

[Avenger]

That's what I ended up doing. Turns out....those bushings don't do so well with the heat, and they burn rather easily. But it's out now....

Turns out the shaft itself was bent, right where it goes through the bushing. I think my friend had used the arm as a lift point, or dropped the trans onto the arm. Heck, he could even have hit it with his lawnmower for all I know! I'm hoping the parts counter can get the parts for him, it's an easy fix if they are available.

[NAJ]

Glad to hear you got it out.
Unfortunatly when things won't budge it usually requires heat or a larger hammer, LOL!!!