Cross Over Shaft - Excessive Wear?

[Michael C.]

I've attached a photo of the engine end of the clutch crossover shaft and the ball stud. I removed them for clean up and not because of any noticeable function issues. The photo doesn't show clearly, but the shaft opening is somewhat "beveled." A fair amount of scoring can be seen in the hole. To my untrained eye the ball stud appears to be OK. At the least I plan to install a rebuild kit because the rubber seal on the ball shaft is badly distorted, and the felt spacers at both ends of the shaft are in poor conditions.

Does the shaft need to be replaced as well? If yes, an tips on what to be aware of in a replacement?

This is on a 69 L36.

Thanks,
Mike
CrossOverShaftWithStud.jpg

[Joe L.]

Re: Cross Over Shaft - Excessive Wear?

I've attached a photo of the engine end of the clutch crossover shaft and the ball stud. I removed them for clean up and not because of any noticeable function issues. The photo doesn't show clearly, but the shaft opening is somewhat "beveled." A fair amount of scoring can be seen in the hole. To my untrained eye the ball stud appears to be OK. At the least I plan to install a rebuild kit because the rubber seal on the ball shaft is badly distorted, and the felt spacers at both ends of the shaft are in poor conditions.

Does the shaft need to be replaced as well? If yes, an tips on what to be aware of in a replacement?

This is on a 69 L36.

Thanks,
Mike
[ATTACH=CONFIG]103223[/ATTACH]

Mike------

The bevel is supposed to be there. From what I can see of the ball stud and cross shaft, they look OK to me.

However, I would carefully inspect the levers on the cross shaft where they are welded to the tubular shaft. These can crack at the weld. If you find even the slightest evidence of a crack, replace the cross shaft.

[Michael C.]

Re: Cross Over Shaft - Excessive Wear?

Thanks for the good news Joe. I'll inspect the welds closely.

[Frank D.]

Re: Cross Over Shaft - Excessive Wear?

If you had undue wear, believe me, you'd notice - this is from my 61 but you get the idea:

[Duke W.]

Re: Cross Over Shaft - Excessive Wear?

FYI back in the late sixties the ball stud on my SWC actually broke... right at the top of the thread. I was able to turn out the threaded portion that was flush with the block surface with my thumb and install the new one. When I rebuilt the engine in the seventies I included the ball stud in the collection of engine parts to be Magnaflux inspected, and it was okay.

Pack the cross shaft with a synthetic EP grease like Mobil 1 and install a grease fitting (can be replaced with the plug for judging) and shoot in some grease with every chassis lube job.

Duke

[Guy F.]

Re: Cross Over Shaft - Excessive Wear?

Mike------

The bevel is supposed to be there. From what I can see of the ball stud and cross shaft, they look OK to me.

However, I would carefully inspect the levers on the cross shaft where they are welded to the tubular shaft. These can crack at the weld. If you find even the slightest evidence of a crack, replace the cross shaft.

I agree. The weld will crack and the lever will snap off without any warning. It happened to me at a stop light in a '74 I used to own. I am sure it has happened to others out there. I ended up driving home without being able to disengage the clutch--lots of stop lights and stop signs to make it interesting.

[Joe L.]

Re: Cross Over Shaft - Excessive Wear?

I agree. The weld will crack and the lever will snap off without any warning. It happened to me at a stop light in a '74 I used to own. I am sure it has happened to others out there. I ended up driving home without being able to disengage the clutch--lots of stop lights and stop signs to make it interesting.

Gary------

It happened to me, too, under similar circumstances. That's how I first became aware of this little "propensity".

Actually, I expect there was a warning about the impending failure. That warning was a tiny crack that went undetected. After all, who periodically inspects their cross shaft for such? I've subsequently learned of other such failures.

[Joe L.]

Re: Cross Over Shaft - Excessive Wear?

FYI back in the late sixties the ball stud on my SWC actually broke... right at the top of the thread. I was able to turn out the threaded portion that was flush with the block surface with my thumb and install the new one. When I rebuilt the engine in the seventies I included the ball stud in the collection of engine parts to be Magnaflux inspected, and it was okay.

Pack the cross shaft with a synthetic EP grease like Mobil 1 and install a grease fitting (can be replaced with the plug for judging) and shoot in some grease with every chassis lube job.

Duke

Duke------


Yes, the tubular section of the cross shaft needs to be packed full of grease prior to installation and periodically "topped off" through the grease fitting.

[John S.]

[Michael C.]

Re: Cross Over Shaft - Excessive Wear?

Not the prettiest welds of the levers to the shaft, but no apparent cracks. However, after removing the other ball stud (frame end) it raises another question. It appears to be bent. What say you folks?
Thanks again, Mike
BallStud-FrameEnd.jpg

[Joe L.]

Re: Cross Over Shaft - Excessive Wear?

Not the prettiest welds of the levers to the shaft, but no apparent cracks. However, after removing the other ball stud (frame end) it raises another question. It appears to be bent. What say you folks?
Thanks again, Mike
[ATTACH=CONFIG]103248[/ATTACH]

Michael------


It's DEFINITELY not supposed to be as-pictured. It has been bent in service. It needs to be replaced, for sure, as fracture is imminent. I'd replace the ball studs on both ends.

You need a GM #3866568 for the engine side stud and a GM #3898610 for the frame side stud. Both remain available from GM.

[Michael C.]

Re: Cross Over Shaft - Excessive Wear?

Thanks Joe.