Stubborn DD

[bucky919]

Ive removed the 16mm from the brake rotor and the 8 13mm nuts holding the Diamond Drive on. Loosened the track all the way. I cannot get it to separate from the track drivers. Ive tried threading the 16mm bolt back in and tapping on it. Ive been under the sled with a 3' 2x4 and 2 pound hammer and beat on it. I cannot get it to move. Any other ideas out there?

 

[markoo]

Driver is probably rusted onto the DD output shaft

 

[m8magicandmystery]

either a 1200 dollar D/D puller (which don't exist ) or brute strength and ignorance...

or find the nineth and tenth nuts..

 

[diggerdown]

Try getting some penetrating oil in there, it must be rusted in. Sounds like you are doing everything right. Guess I never counted how many bolts hold it in but I'm sure you've double checked that. I would turn the through shaft bolt all the way in then back it out about four turns, run a heavy rod to it and give it some good hits with a hammer. I haven't had one that wouldn't come with enough beating on it. You could also try gutting the gearbox and tap from that end on the shaft while trying to pry the case out. Keep soaking it and if it's possible to get a hot air gun close without melting the drivers try that too.

 

[bucky919]

Ill have to let it soak with some pb blast over night, I just cannot get the thing the move, another project that should take a half hour turns into a day project lol.

 

[skidooboy]

look up in the top of the footrest area inside the motor area behind the secondary. there is a retainer nut up there for the DD easily missed. i was trying to remove my DD and couldnt get it to budge, then i saw belt residue hanging in the upper foot rest area (behind the stiffener shield for the footrest) two torx screw hold the stiffener on the inside of the motor area, and two hold it where your toes would hit if they were in the foot wells. remove that, and look up top to the right of the secondary. Ski

 

[Coldfinger]

x2 what Skidoo said

 

[Sledbrain2]

Once you have all the bolts out it should move a bit. Best way I found is to use left hand on shaft wiggling and the right hand pulling from inside tunnel. Should get it to move, then its just back and forth until the stars line up for you and she come off all at once.

 

[CB.8]

Loosen the track up. This helps a lot!

 

[m8magicandmystery]

Loosen the track up. This helps a lot!

he did...

 

[bucky919]

look up in the top of the footrest area inside the motor area behind the secondary. there is a retainer nut up there for the DD easily missed. i was trying to remove my DD and couldnt get it to budge, then i saw belt residue hanging in the upper foot rest area (behind the stiffener shield for the footrest) two torx screw hold the stiffener on the inside of the motor area, and two hold it where your toes would hit if they were in the foot wells. remove that, and look up top to the right of the secondary. Ski

Yes I removed that bolt, there is defenitly no bolts holding it in place. The whole DD moves just won't break free of the shaft. Ill take a fresh look at it the tomorrow and eat some spinach for lunch and hopefully it will let loose.

 

[rdr99]

Is the bulkhead bent up underneath the Diamond Drive? I have had that little lip bend up and put pressure on the drive before. Had to beat the lip back down with a hammer and large punch.

 

[ultrasks700]

Put the 16mm bolt about 1/2 way back in. Put the socket on it with a long extention and give the extension a couple good wacks.

Now with that being said, i always lube the crap out of the DD splines before putting it back in.

 

[m8magicandmystery]

it is possible...though unlikely that the splines have worn into each other and locked and you may have to reverse your thinking and compress the shaft and D/D together and twist back and forth and in and out with two sets of hands..

 

[CB.8]

he did...

Sorry, posting while tired can lead to incomplete comprehension of the material.

 

[av8er]

pull the rubber vibration piece from behind the DD

be sure to take the 4 screws out by the footwell, made that mistake before after beating it like a red headed step child, and bending the pizz out of the aluminum footwell piece.

 

[shane019]

If you have someone to give you a hand lightly pry around the diamond drive case on the clutch side with a small prybar and have other guy tap from the inside by the drivers with a block of wood. Once you get it to move a bit guy with prybar can start wiggling the case while other guy taps on it...

 

[tkuss]

I had the hardest time getting my DD out last summer. Basically I threaded that 16MM bolt in half way and hit is as hard as I could with a big hammer. When its rusted in, its a b*tch to get out. But I didn get it out. Don't be afraid to hit it hard, just triple check to make sure all the nuts holding it on are off...

 

[HardKor]

my $.02...

Just saying... the drive shaft and drivers WILL fit through the DD hole, in a worst case scenario... (had one of those once!) It's not easy, but patience and manipulation, you can get it out as a unit --- and then beat it to death!

 

[Team Pigeon]

Another issue I've run into was the bulkhead lip below was curled up into the dd preventing it from coming out. This occurred pre-twisted tea era but post pilsner lunchtime specials.