Technical Gearbox/Clutch/Flywheel/Core Plug Removal with students

bean · Jul 19, 2011

Thought i would start a thread on my current project:

I teach some Motor Vehicle at Secondary School and I am bringing my cinq in to replace the core plugs on gearbox side with my students helping, starting tomorrow.

Hope it goes well

It's a good chance for them to learn other things and be part of getting my car fixed up.

Any tips for this before I start tomorrow??, aiming to give plenty of updates especially when we hit problems! NS Outer CV is gone too so we are sorting that.

Here's the ramp ready:

whitz · Jul 19, 2011

bean said:
Thought i would start a thread on my current project:

I teach some Motor Vehicle at Secondary School and I am bringing my cinq in to replace the core plugs on gearbox side with my students helping, starting tomorrow.

Hope it goes well

It's a good chance for them to learn other things and be part of getting my car fixed up.

Any tips for this before I start tomorrow??, aiming to give plenty of updates especially when we hit problems! NS Outer CV is gone too so we are sorting that.

Here's the ramp ready:

yep done let the idiots touch the car

should be 3 1/2 hours tops

Ash

rallycinq · Jul 19, 2011

I presume you are fitting a new clutch while in there.

Cheers

D

bean · Jul 19, 2011

Gonna "filter" which kids work on the car

I replaced clutch at 90K and now car is on 130K should i still change it?

Clutch feels fine to me.

3 1/2 hours would be great but i feel it may take longer.

Will keep this thread updated with progess tomorrow.

Thanks

Nath

dave · Jul 19, 2011

bean said:
I replaced clutch at 90K and now car is on 130K should i still change it?

yes especially if you are teaching, you should teach that you may as well put in a new part that is cheap instead of having to strip it all down again another day

bean · Jul 19, 2011

good point, will have a look at getting a replacement.

One driveshaft question: I need to replace the NS one as CV is broke but i'm guessing the other has to come out too? Do i remove it from its cup? Will i have to renew the clip that holds the boot on?

It's gonna be a learning day for me too, the blind leading the blind....

Thanks

Nath

dave · Jul 19, 2011

i always drain the box and remove the shaft and cup as 1

rallycinq · Jul 19, 2011

However.

I always leave the cups in the box and take the spiders out of the cups.

Yes you will have to replace the clips on the outer CV with the metal clips that should come as part of the kit.

You replace the CV, not the whole shaft.

If you don't have 'clip pliers' a set of side cutters will nip them up, just be careful you don't cut right through.

Cheers

D

dave · Jul 19, 2011

or you can use these for clip pliers

ones from pound shops are best they come blunt

bean · Jul 20, 2011

Thanks for help,

Slow progress so far today due to fuel leak coming from spout of new tank. No matter what i do i cant seem to get a tight joint that doesent leak, any ideas? Got the rubber sleeve on and a new jubilee clip.

We have the wheels off, hub nuts off and in the process and popping the lower ball joints. Got nuts to the end of the thread but can't ge them to pop yet, any advice?

Went to drain gearbox oil and nothing came out!

Thanks

Nath

Eklipze3k · Jul 20, 2011

Are you draining the box from the right place? An allen key on the lower rear of the box?

bean · Jul 20, 2011

Maybe i'm not then, just got one DS off and not much gearbox oil coming out,

now for OS driveshaft.

bean · Jul 20, 2011

Right,

found the real plug for gearbox and drained oil out (hardly any there!) got kids to disconnect clutch cable, gearbox earth and start on gearchange bracket. I really can't seem to pop the gearchange ball joint,

any tips?

Thanks

whitz · Jul 20, 2011

pry bar and dont forget the speedo!

Ash

rallycinq · Jul 20, 2011

Needle nose pliers?

Cheers

D

bean · Jul 20, 2011

Slow progress but getting there.

All cables and ball joints popped but we really can't get the OS driveshaft out of the gearbox! It is rounded so can't pry it out with a bar.

Any tips? I'm reluctant to seprate the driveshaft from inner CV but is that the only option?

Thanks

ycming · Jul 20, 2011

Undo the 2 strut bolts there is enought movement to pop the shaft out the box.

Ming

rallycinq · Jul 20, 2011

bean said:
I'm reluctant to seprate the driveshaft from inner CV
Thanks

Why?

I also don't understand what is 'rounded off', if you are taking the cup out, its just a snap ring.

Cheers

D

whitz · Jul 20, 2011

give it a clout

my "specialist" took is a big flat dull punch that you knock it out with

Ash

bean · Jul 20, 2011

rallycinq said:
Why?

I also don't understand what is 'rounded off', if you are taking the cup out, its just a snap ring.

Cheers

D

Guess i'm just thinking of all the grease everywhere!

I've got some circlip pliers so i guess thats the best option.

Its rounded as in the plastic cut that attaches near the gearbox has no lip on it to pry it out like the other side did.

I can't even give it a whack as due to the round bit.

Will post a pick up later, its been a long day making sure no kids round off any bolts!

Thanks

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