pug 505- the manual gearbox conversion is starting!
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  1. #1
    Fellow Frogger!
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    Default pug 505- the manual gearbox conversion is starting!

    pug 505- the manual gearbox conversion is starting!-.jpg
    hi guys, the ba7/5 box is on its way to get installed, it's from a 92 wagon with a cable operated clutch.
    just a couple of questions for the beginning:
    1. is it necessary to replace the ball stud in the clutch housing, and if so- how do you remove it? (a new one was ordered just in case).
    2. can the rubber damper be fitted without removing the ball stud? it was missing, a new one was ordered.
    3. is it necessary to get a new release fork?

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    thx

  2. #2
    1000+ Posts robmac's Avatar
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    I'd replace the fork and the thrust race because it not something you want to do later

    And make sure the clutch is sound and flywheel smooth too for the same reason.

    If you have the funds a full clutch kit plus a fork is not a bad idea.

    I've seen a pivot ball break, but forks do regularly (they bend actually)

  3. #3
    Fellow Frogger!
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    thrust race? what is it?

  4. #4
    1000+ Posts Beano's Avatar
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    Just the outer part of the ball, and slightly to one side.....where the fork presses on to it.

    I did replace a ball stud once , and if I recall correctly, I punched it out from the rear, after taking off the bell housing. I then hit in a new one with a copper-faced hammer (though once you get it started, you could use a bit of hardwood between it and the hammer)

    Absolutely and definitely replace the throwout fork. I have seen a few broken ones, and and heard about many more. They are known to last about one and a half clutches. In other words, need to be replaced every time.
    Last edited by Beano; 2nd March 2016 at 09:03 PM.

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