How to remove Lewmar H2/H3 gypsy?

[hlev00]

Somehow the two halves of our Lewmar H2 gypsy have gone out of alignment (img_3644). This is causing all sorts of problems with the chain jumping off the gypsy. According to Lewmar support, there are a few pins that keep the two halves in alignment and these have apparently sheared off. Over the winter I am planning on replacing this gypsy with one for a different size chain.

I am hoping to get this gypsy off and manage a short term fix by replacing the pins. A real short term hack would be to just realign the two halves and hope for the best as right now the two halves do not move. Either way I need to be able to pull it off. Yes, I did try a little persuasion to get the halves realigned but didn't pursue that too far due to fear of busting something.

The gypsy cover comes off quite easily, but that's as far as I could get without getting inventive and likely screwing something up. I've asked Lewmar for advice but thought I'd reach out here to see how others might have approached this problem. For reference img_3664 shows the outboard face of the gypsy and the clutch cone. The arrow is pointing to where a "drive pin" is supposed to be inserted. My guess is that this is needed for gypsy removal.

Thanks all,
Harry
s/v Juno, Beneateau 423

[Paul L]

Did you unbolt the stripper arm?

[hlev00]

Originally Posted by Paul L

Did you unbolt the stripper arm?

I realized that this would be required so I started there, but found that the bolts are pretty seized. Especially the bolt pictured here. The bolt hex sockets seem pretty soft and a little "L" shaped allen wrench seemed like it was going to strip out the hex socket, so I turned my attention to seeing if I could get the gypsy loose.

[Paul L]

Pretty sure the stripper has to come off. You might have to get brutal with it and fix the damage afterward.

[LadyStardust]

Just for ref, as I know this is an old thread, but yes, the striper needs to come off, I had to drill off the allen screw heads, then with WD40 and mole grips, I was able to remove the screw stubs. With this off, the gypsy will pull off, and you can access and clean the inside clutch cone.
I'm now trying to work out how to get the motor / gearbox out of the housing.

[NYSail]

I am looking at this project for this weekend as my h2 does not manually free fall due to lack of use (free fall release). Any other suggestions while removing?

Thanks
Greg
Beneteau 423