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twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
  
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| Gearbox removal - advice required |
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Anyone removed a manual gearbox. 
We are unable to access the bolt at the top tf the bell-housing.
Any advice on improving access would be gratefully received.  Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
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 29th Jan 2011 11:06 am |
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Bodsy
Site Sponsor
Member Since: 06 Nov 2006
Location: In the Clubhouse
Posts: 21361
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Glad you got it sorted twoakers. Bodsys Brake Bible
D4/D3 Remote FBH heat kits
BAS Remaps/ EGR Blank
Transmission Flush
Software updates/enabling
Clock/ SNOTM /3Flash / 4x4Info /BT Update /Service Reset/Error Codes / Gearbox Reset
See It Here
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| 30th Jan 2011 5:13 pm |
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bellautos
Member Since: 02 Feb 2006
Location: NorthYorkshire
Posts: 2532
 
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Lower the rear of the box, use a few extention bars that go over the top of the box and put the ratcket at the very back of the box.
Very fiddeley but doable  Dont forget to put all the bolts back in the crossover pipe and bracketry when you refit.
Pete
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| 30th Jan 2011 7:03 pm |
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twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
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Thanks guys for your support and advice. 8)
At least it confirms that we are working along the right lines.
It's a good job I am being helped by my brother.He started an apprentice mechanic in about 1973 and ended up as a workshop manager. (He has a Disco 2) 
On Saturday we worked out that when LR simply said "remove the 14 transmission bolts" what they meant was you had to go through lots or try it and see scenarios 
First we had to lower the transmission. Just like they said except it would not lower onto the chassis cross member until we disconnected the exhaust from the turbo and the air intake on top of the engine from the intercooler. 
Then we had to work out how to reach those top bolts including the exhaust bracket bolts booth side and top. This was done almost exactly like you said Pete. Except that we found that we could get to 'em with extra long socket extensions and an air ratchet driven through the gear change hole from INSIDE the car. 
Then it was fairly easy to pull it back and drop it down using my nice new shiny transmission jack with the odd persuasion from a pry bar.
So we are pleased to say it's now on the floor of the Barn. 
Mt brother then suggested that we check it for the fault
Remember why we were taking it out....?
.....it would not engage reverse gear. Something was stopping the gear lever from being 'knocked across' to the left into the reverse gaer gate.
Now we all know that this model has a ZF 6S-53 box don't we 
Well on this model the 'knock across' is controlled by a detent ball and spring arrangement.
Taking the top cover off, the one with the gear sensor, revealed the detent and you guessed it. It was baulking.
Unscrewing the plug revealed that the retaining cir-clip has broken into about 4 pieces.
This allowed the detent to travel in too far and baulk when trying to engage reverse gear.
So having spent loads of money so far on gear stick, knob, linkages, and replacement gear box etc etc. It was simply a cir-clip worth about 4p 
Never mind, I had to remind myself that, we have a nice 'new' low mileage box to go in with nice new linkages and knob and the clutch will also be done which we are at it. So it makes it all worth while 
So we had yesterday off (it was the Sabbath) apart from a sneaky inspection of the clutch revealed that it was 'as new' (2.9mm left of 3.2mm) 
Today we are slipping in the 'new' box if we can remember how to do it 
Now does anyone know where I can source a ZF cir-clip........ Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
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| 31st Jan 2011 9:36 am |
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twoakers
Member Since: 15 Nov 2010
Location: Harwich
Posts: 367
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Yesterday we got most of it back together OK.
Today we do the fancy stuff inside and road test it
When the dust has settled I will write an article for you guys with photos.
Does it need to to go on the forums or on the Wiki thingy? Cheers, Dave in Essex
D3 07 TDV6 HSE
Clubs - Turbo changed, EGR valves replaced, General Grabber ATs, Hawkeye FC reader, Front/rear wishbones, manual gearbox change, autobox flush, cam belt change, HPFP belt change, oil pump change....
Coachman Laser 650/4 caravan
Amateur Radio Callsign - G8PAI
Playing with Big Boys Toys!
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| 1st Feb 2011 9:31 am |
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