General Stubborn gearbox....

[Tabblink182]

Since my thrust bearing went on my car i decided to have a go at replacing the whole clutch...

its all gone well untill we tried to actually split the engine and gearbox apart. Everything is dissconnected and the gearbox has pulled out to a certain point.

there is a gap of about 10-15mm all around the bellhousing but its jammed and will not move any further ! Both the engine and gearbox are jacked in a position where they are dead in line so it should just slide out ???

any help would be appreitated

thanks

 

[Chas Uno]

Have you removed the small metal plate that covers the lower part of the bellhousing? If that's still in place it will catch on the flywheel.

And is EVERYTHING disconnected? Driveshafts/ cables/ linkages/ mountings etc?

You might also find one end of the gearbox catches the subframe (the driveshaft/ differential housing at the back - not always too obvious). Maybe let the engine tilt downwards a bit at the gearbox end and then try pulling it out. If the engine and box are totally level then I don't think they will pull right apart.

 

[Tabblink182]

when i say "level" i mean the relationship between the engine and the gearbox itself.

the engine in the car itself is pointing downward, everything is dissconnected and i have removed that plate...

it just wont budge

:/

 

[fingers99]

If there's a big gap, then careful application of a rubber mallet and/or a pry bar (very carefully with this!) works wonders. Continue to support the gearbox while you're doing this and be very careful it doesn't fall on your head!

 

[Tabblink182]

mallets on the bell-housing, levers everywhere i can get them, the thing still wont budge

its like its ceased at the shaft... it will pivot all around the central point, but wont slide out at all, pulling and shaking it nearly takes the car off the axel stands !!!

 

[fingers99]

Try firing some WD 40 or suchlike in the direction of the splines. But, chances are that the gap isn't even, which is why it's stuck. Up and down and side to side while pulling should do it. Mindee fingers!

 

[Tabblink182]

after another hour of trying to get the garbox out using fingers method ive given up as its now dark

just a quick question, as the haynes isnt that cIear

when it says to remove thw driveshafts, ive just dessconnected them from the trpod bearing end, the inner cv joint into the diff is stiII in pIace, this is correct right ?

 

[fingers99]

Should be OK. Only issues I can see are about room to move!

 

[Tabblink182]

weII god knows whats going on

:/

i thinks its just ceased onto the cIutch pIate

im beggining to think it wouId have been better to just pay the garage 2/3 the price of teh car to do it

anywho iII continue work if i get home from work in the Iight

ive aIso taken Iots of digi pics and wiII write a guide when (if) im done =]

thanks for the heIp

 

[Chas Uno]

after another hour of trying to get the garbox out using fingers method ive given up as its now dark

just a quick question, as the haynes isnt that cIear

when it says to remove thw driveshafts, ive just dessconnected them from the trpod bearing end, the inner cv joint into the diff is stiII in pIace, this is correct right ?

That should be ok as long as the driveshafts aren't in the way. What I did on my 899 engine was remove the driveshafts and hubs as one unit. Easy to do (undo 2x strut nuts/ bolts, undo trackrod end, undo suspension arm lower bolt and undo anti roll bar if a Sporting). Then the hub and driveshaft can simply be removed from the car as one unit giving you more room to work in.

One thing I was wondering Tabblink. There is a BOLT on the bellhousing that is secured by a NUT. This is just below the starter motor at the back of the engine and is easily overlooked. If you've only partially undone it then you might get the problems you described.

I must admit that normally I haven't have too much trouble taking gearboxes off. It's getting them back on and lining up the input shaft with the clutch that can be an almighty pain. I had this happen on my recently acquired Uno 70 SX and it took 2 hours to get the f**ker back on! I was sweating like a horse, swearing like a trouper and just about to give up thinking the clutch splines must have been incompatible when "clunk", the bastard slid on!

Anyway, good luck and hope you manage to get it removed eventually.

EDIT: Totally different subject but what IS that thing in your sig Tabblink?!!!!

 

[randomizered]

Is the starter motor removed?

 

[Tabblink182]

Is the starter motor removed?

yes

One thing I was wondering Tabblink. There is a BOLT on the bellhousing that is secured by a NUT. This is just below the starter motor at the back of the engine and is easily overlooked. If you've only partially undone it then you might get the problems you described.

EDIT: Totally different subject but what IS that thing in your sig Tabblink?!!!!

yeh, i didnt realised that one on the first, but it is off. the gearbox unit is completly loose everywhere as it even spins slightly!!!! it just wont slide off !!!

the sig, tbh i really have no idea, i got quite into making sigs at one point.... it was just a cool looking render i found.. XD

 

[rallycinq]

It could be that your release bearing is right through the cover plate. Is there enough room to undo the bolts holding the cover to the flywheel?

Cheers

D

 

[Chas Uno]

It could be that your release bearing is right through the cover plate. Is there enough room to undo the bolts holding the cover to the flywheel?

Cheers

D

Good point. If the clutch was totally shagged and making a racket then that could've happend. What were the problems with the clutch that required it to be changed?

If the bellhousing will come away by a few centimetres you should be able to get a 10mm spanner to undo the holding bolts. I think there's only six of them?

I'm very curious to know what is stopping the gearbox from coming off!

 

[Chas Uno]

the sig, tbh i really have no idea, i got quite into making sigs at one point.... it was just a cool looking render i found.. XD

Ah, so my curiosity is going to be left hanging! :bang:



I can't work out if it is some kind of monster (no, not REM ), an alien in a space suit, something coming out of fire or, or, or... :chin:

 

[Tabblink182]

It could be that your release bearing is right through the cover plate. Is there enough room to undo the bolts holding the cover to the flywheel?

Cheers

D

Good point. If the clutch was totally shagged and making a racket then that could've happend. What were the problems with the clutch that required it to be changed?

If the bellhousing will come away by a few centimetres you should be able to get a 10mm spanner to undo the holding bolts. I think there's only six of them?

I'm very curious to know what is stopping the gearbox from coming off!

no, its not off far enough to get to the bolts and there are nine in total i think.... a shame.... ive now got hold of some 3ft long pry bars, so ill give them a go tomorrow if i get home in the daylight =]

well, at first it started rattleing, at first i thought it was the exhaust. but as it got louser it was apparent it was the thrust bearing, the clutch wasnt in the best of shape either tho :/ and after endless amounts oif adjusting the cable, the thrust bearing eventually went =[

Ah, so my curiosity is going to be left hanging! :bang:



I can't work out if it is some kind of monster (no, not REM ), an alien in a space suit, something coming out of fire or, or, or... :chin:

i really have no idea, i got it from gamerenders.com, but theyve now changed so you have to be a member to access there gallery =]

its not comming out of fire, i made all the background and stuff in photoshop.

 

[rallycinq]

There are only six bolts, the other three are dowels.

I am pretty sure the release bearing is the wrong side of the forks, so just haul it out.

Bear in mind the garage would have phoned you half way through the job and told you that the job was going to cost more because of this problem. With the box half out the car you would have had to pay.

Have you taken the coil pack off to get better access?

Cheers

D

 

[Tabblink182]

There are only six bolts, the other three are dowels.

I am pretty sure the release bearing is the wrong side of the forks, so just haul it out.

Bear in mind the garage would have phoned you half way through the job and told you that the job was going to cost more because of this problem. With the box half out the car you would have had to pay.

Have you taken the coil pack off to get better access?

Cheers

D

no, i didnt really want to take anything off that i dont have to... will it help alot ?

also, hauling it out just nearly takes the car off of the axel stands lol, like i said, i have some 4ft long pry bars ill try this weekend, or friday if i get home from work in the daylight.....

=]

 

[randomizered]

Just cut 4-6 wooden wedges and hammer them around the gap. Probs safer than pulling it so hard it nearly comes off the stands.


I actually lifted the front of my car off the stands once, removing a hub nut lol.....must have been stronger than i realised. Manged to lower it back on ok though!


Kristian

 

[rallycinq]

Changing my box this week I had the axle stands just in front of the point of balance. When I leant on the front the rear wheels came off the ground!

Cheers

D