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Author Subject: Gearbox?clutch
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #1
PLEASE DO NOT POST HERE

All comments Here

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 18th May 2005 at 20:24
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #2
Right
First things first,

Park the car some where, where its not going to get in the way..

Some where with enough space both sides, And out the way of any kids


First up remove the battery,
Undo these 10mm bolts

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 20:36
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #3
Remove the battery, and your looking at these.
Undo all 4 (13mm)

If you have a strut brace now is the time to remove it. Remember to put the bolts back in again

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 20:41
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #4
Next up remove the Ecu cover, Pull up the silver lever/bar and pull loom off

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 20:44
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #5
With the battery box outta the way, there is a plate underneath, 4 bolts hold that in place.

Undo them, 13mm again

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 20:45
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #6
Know remove the air filter, I have Kn but im sure its easy enough for what ever you have

Undo these 2 and remove pipework

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 21:57
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #7
Undo these 2 cable ties.

DONT snip them, they undo easy enough

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 21:58
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #8
Undo this little sub plate, its 13mm, Put the bolt back in after and you wont lose it

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:00
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #9
Under the plate there is a 17mm bolt, Its a bell housing bolt so is quite a long one

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:02
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #10
A bit further out, so you can see

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 18th May 2005 at 22:05
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #11
Remove the clutch cable, Just pull at this end and just push out of the way,

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:07
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #12
Unplug this sensor

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:09
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #13
Unplug this brown plug, Its floating round under the thermostat

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________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:13
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #14
Undo this little fella here..
Its a 11mm

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:16
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #15
A bit closer

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Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

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Posted 18th May 2005 at 21:07
Welly Forum Admin

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Registered: 11 Jan 2004

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Post #16
This is the release arm for the clutch, There is a spring that goes over, But i removed it so you can see the pin.

To get the pin out, you will need some Mull grips, and some brut strength..
Twist it round its circumfrance, to loosen it off, then put the grips on front to rear and lever it off..

CAREFULL OFF THE RAD!!

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:23
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #17
Lift off the lever arm
And this is whats under, Carefully prise the plastic lug out

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:26
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #18
Next is the 3 gear linkages,

Pull them up, being carefull not to ben them, Or use a screwdriver under and prise up.

If your gunna loose any skin now is it LOL

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:31
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #19
Next get under and drain the fluid..
Undo this, Its just slighty smaller than a 3/8 ratchet.

Remember you will need a new copper seal

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 12th Nov 2005 at 22:50
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

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Post #20
Next up is the speedo housing..

3 13mm bolts, (the other is tucked up the other side)

There is also a plug that needs undoing as well, its inside a silver foil bag

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:46
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

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Post #21
This is the bearing between the half shaft and drive shaft...

These little hockey stick bolts need to be undone most of the way, when you can turn the BOLT 360 degree's its far enough..

These are 11mm

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 22:51
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

Status: Offline

Post #22
Next up get the car up on Axle stands.
Keep them as far forward as posible, so you have less to drop the box.

Next remove the pin and cover for the hub nut, its a big un 36mm
Get a friend to hold the brake while you undo this one..

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 23:06
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

Status: Offline

Post #23
Drop the ball joint.

undo the 17mm bolt, and pull the wish bone down and free the hub

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 23:15
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

Status: Offline

Post #24
When you have both hubs free, pull them to one side and remove the drive shafts..

remember the drivers side has the speedo housing which needs to be removed and a rubber stopper..

pull them STRAIGHT out so you dont damage the driveshaft seals.. Although it is advisable to change them

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 18th May 2005 at 23:20
Welly Forum Admin

Location: Brizzle

Registered: 11 Jan 2004

Posts: 21,797

Status: Offline

Post #25
Put something under the engine to support its weight when the gearbox drops.

Crude but affective, although im using a towel to stop any damage

Put a jack and axle stand under the gearbox, dont put them right under the box, cos you will need drop it slighty

Welly has attached the following image:

________________________________________

Life is a lie. The only certainty of which is death. Go live and enjoy yourself. The clock is ticking

Vrs power!!
Posted 24th May 2005 at 20:47

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