Hi guys, I currently at that point of wishing to set fire to my car after a failed attempt at a gearbox and clutch change. First off one of the exhaust bolts broke off, there is a little thread sticking out, but this was the least of my worries. Managed to get the flywheel off, new clutch in, new pressure plate on and all was going good. Anyways I have spent 2 hours yesterday and another 8 hours today trying to get the new gearbox in and I have had enough. I can't get the driveshaft in no matter what angle I go or how i line up the box I used a proper clutch alignment tool and all went in really well. I think I am going to pull the engine next weekend...might be easier than trying to get the box on from underneath. What a rubbish weekend. I HATE MY CAR!!!!!
I really feel for you. I did a clutch on my Triton laying on my back in the shed and never again. I had a prick of a time getting the shaft lined up also. Ended up lifting the box up on a trolley jack with a bessa brick in between and a lot of blood sweat and the queens English latter the mother *&&^ went in. All I can say NEVER AGAIN. A mechanic mate told me to jam a wood cho cunder the front of the motor to tilt it back a bit and I believe this did help. Cheers Dave
Check the spigot bearing for damage and make sure the gearbox and crank are exactly lined up. Can be quite hard to do when laying under the car. I always try and do it with the engine out of the car.
Put yail shaft on I have done it 3 times now, used a trolley jack and when partially in, I put the tail shaft in and rotate slight and try pushing in, if still no good repeat proses, it should go might just take a few attempts. best of luck
Cheers for the input guys. This has been a totally demoralising process. I have checked the area around the clutch and all seems good. Haven't damaged anything. It seems that I can't get the bell housing up high enough to line up the driveshaft without it hitting the top of the tunnel. I then tried angling the box with the back down and go in and up be still no dice. Just seems like its about 5mm shy of getting the driveshaft into the actual clutch, in height. Looking through the starter motor hole I just can't seem to get it right. Hope this bloody gearbox I go is the right one, That would be a total nightmare if not. Are na and tt boxes much different, just hope I have been sold the right one. Beavis
Jam a block of wood under the front of the motor like I did. It will angle the back of the motor down slightly and make a huge difference. Dave
i did think about that but i could only see to jack the oil pan and I did with some wood and the motor didn't move. Is there a place after the cross member that I can jack up on? Beavis
Haha, why didn't I think of that, must have been the fatigue from the day. I couldn't even lift the trolley jack when I was packing up for. Do I have to disconnect anything above to aid tilt? Will I damage the intake hoses, or something at the back of the engine? Cheers Beavis
You only need to lift it 2 inches max. Just do it slowly while watching the fan/hoses and radiator but should be fine. That little angle will give you more room on the bell housing. Try and get an extra set of hands. Cheers Dave
I feel your pain mate. My good mate and I have worked on cars almost all our lives. Done it all, conversions, clutches, turbo rebuilds, etc... etc....but there is one thing we both agree on and that is we ABSOLUTELY HATE removing g/boxes. On your back trying to align the bastard, heavy as. A few yrs ago, when the rear main seal went. I gladly paid for that to be done and have not regretted it EVER. There are some things best to pay money for and save your time and knuckles and getting squashed to death. Hehe.... Takes a shop almost next to peanut time to remove and refit the box and charge about $400. If you have a hoist though and the right equipment then it is no problem to DIY. Peter
Hey mate I have done it a few times now with minimal trouble, you should be able to get the box high enough into the trans tunnel with no probs. Also are you using an n/a box on a TT? If so you will need to grind the inside of the bell housing near the starter otherwise you won't clear the flywheel. If you clutch is lined up perfectly, get the box up and start to move it upto the motor. You should have it around the pressure plate before the input shaft enters the spigot, also be sure to keep the same distance all the way around the box to the block so the input shaft stays in line with the spigot/clutch.
Thanks for all the tips and tricks. Going to have a go after work today and see if I can at least get the box in. Hey mate, Thanks for the tips, I think the engine has leaned forward and thus I can't get the box high enough to get the drive shaft in. I am literally 5 mm too low with the box hitting the tunnel. I have checked the box and it seems to be a TT box. I'm hoping the that tilting the front of the engine will give me enough to get the drive shaft in. Cheers Beavis
Yer absolutely! Im at the point in my life where i attach a money value to my time and effort, especially when it comes to laying under a car trying to heave a gearbox into position as Geron sagely points out. Many years ago laying under the olde Ford Capri up on stands and i got myself stuck under there. Laying under the car on front stands only with the gearbox laying on my chest and guts and not only had i run out of energy to heave the box up into position, I couldnt wriggle myself from under the fekkin thing either and there i lay trying to breathe with the weight of a Celica Steel case 5 speed/bellhousing on my guts and chest pinned under the car and unable to get out............ I did get out eventually by myself but it took all the nerve I had in me not to panic trapped under there for what seemd like a long time...... So yer M8, crank the front of the motor up which will tilt the back down to get the clearance you need. When doing this job the hard way as you are, its a better feeling than being blown by an 18 year old hardbelly when that prick of a thing finally clonks into position... Good luck bloke. Dont get mad with it, get even! E
^ I never feel comfortable working deep under a car, specially doing that sort of work without someone else being around for those very reasons.
Yep, this is a two man job minimum, and you need decent quality and height stands, and a decent trolley jack to carry the weight of the gearbox. Even then it's a pita job lol [TIS]
lol! Thanks again for all your replies!! Just popped outside and jacked the front of the engine. Seems like the back went down about 10-15mm. Just popped off the intake hoses and made sure nothing was crushed at the back of the engine. Should be plenty of room now to get it sorted. I was just about to get changed and give it a go under floodlights but after the smell of oil and gearbox fluid, I decided that getting dirty for a 3rd day in a row with diminishing light was just silly. Bring on the weekend or a day off work sick.....cough cough....... Beavis
