Guide: how to remove gearbox (with basic tools)

[mcjacko1987]

never come across a guide with pics and iv just had to remove my box (again) due to a leak and knackard box so thought id take some pics along the way and hopefully will come in handy for others.

first off the basic tools:

theres 2 17mm spanners as you will see both are needed to remove the wish bone. the alen key is 8mm. flat head screw driver and an 18mm socket.


1st things 1st jack up passenger side and remove wheel, stick on axle stand

also stick a jack under the engine (under the sump, use some wood inbetween the jack) and stick an axle stand under there too again with wood on top

drain out all the gearbox oil. there is a square plug on the side of the box, you will see it if you look at the box where the wheel was. (sorry dont have any pics as my oil had already broke free). there should be 2ltrs of oil in there so make sure you have a large enough bucket or bottles to catch it.


disconnect the battery and air intake and remove them from the bay


remove the 3 nuts holding the tray in and remove it (if you have power steering then there will be a plastic clip that you unclip from the power steering hoses just to the left of the tray).

you can now clearly see the clutch adjuster cable
use 2 spanners here 13mm and a 10mm. put the 13mm on and keep it still whilst undoing the 10mm nut (do not take it all the way off the thread)

once the 10mm is down a few inch start undoing the 13mm, you want to do this untill you can pull the plastic insert out the metal arm with the cable, then feed it threw the slot on the left of the ring on the arm

then threw the other slot where you will see a small gaitor

move it out the way.
then you need to remove the starter motor. this is just behind the engine connected to the gearbox.theres 3 bolts here holding it on and an earth wire on the end i remove just to make it a little easyer. 13mm i think these all are.
first remove the earths
starter motor
earths
you then have 2 bolts on the starter motor side and one on gearbox side.
one gearbox side (the bottom bolt, not the allen key one)
once off remove out the way.

remove plug off the crank sensor

crank sensor
remove the crank sensor on the front of the box
this is done by removing the bolt then pulling it off towards the gearbox


now unplug and remove sensors on plugs and earths on the box, there are a few so iv took pics of locations. one is down behind the box and its one of them plugs with a pin on that you press the pin and pull the plug (use a screw driver to press the pin is easier to remove).
the anoying one is down there

earths:


theres a plug just next to that earth.

you then need to pop off gear selection rods. i use a spanner just to pop them. theres 3 in total, 1 long arm near the top of box and 2 small ones down the bottom, all these are situated behind the box, you cant miss them.

[mcjacko1987]

you also need to remove the wish bone on the passenger side.
there is a bolt where you will need the two 16mm spanners here

hold the nut still whilst turning the bolt (or visor versa , however you approve)

once the bolt is out you need to pop the wishbone off. i used my trolly jack bar. wedged it behind the disc ontop of the tip of the wishbone and just pushed the bar down


pull the passenger side driveshaft out the gearbox



remove the gearbox mount from under the car
i used the 18mm socket and a 17mm spanner (this is done the same way as the bolt and nut on the wishbone)



almost there now......

next remove the 3 alen key bolts (8mm key) that hold the box on the engine



now stick a jack under the gearbox (just incase)


now go over once again that all plugs and wires going to the box are removed.
also you may notice i have a 4 branch manifold. some 4 branches and all standards have a mount also (or so i think) you should also remove that.
also all the steps above can be done in any order just as long as all is done.

now ensuring again everything is removed from the box, undo the top mount.
1st remove the 18mm big nut off the thread you can see, then go about removing the other 2 bolts that hold the mount to the chassis






now for the hard part

pull wiggle and use all your strength to remove the box. play about with the jack under the box and jacking the engine also and eventually it will come out

you will then have......

one removed gearbox

if you wish to remove the clutch then there are 6 star key bolts T45 i think on the clutch case. i havent removed mine as i know its new but heres a pic because im kind like that


as you can tell its a long guide so iv probs made some mistakes along the way in this i will run over it after my tea.


sorry but have to note i take no responsibility for injury or damage to your car

hope this guide helps some of you

[Tontsy]

seeing as needing a new gear box is possibly the most common thing on these cars, im suprised its taken so long for a how to!

well done mate.

[Pricklep]

Looks alright. Id rather take it to a garage.. looks a chew on, ha.

[mcjacko1987]

Originally Posted by Prickle

Looks alright. Id rather take it to a garage.. looks a chew on, ha.

haha its not that bad tbh one you've done it once.

and cheers tontsy

[BertieG]

dont forget to drain the oil first, instead of knock a shaft out by mistake before you are ready, spread a litre of box oil down the drive and never stop hearing about it by your parents who are fucked off with the ruined drive......

[mcjacko1987]

Originally Posted by BertieG

dont forget to drain the oil first, instead of knock a shaft out by mistake before you are ready, spread a litre of box oil down the drive and never stop hearing about it by your parents who are fucked off with the ruined drive......

edited cheers mate.
forgot about that seeing as though i already had a leak lol

[outrage_uk]

Good write up bud...

You need to stick "Drain gearbox oil by removing the drain plug..."
before... "Pull the passenger side driveshaft out the gearbox"... though

[outrage_uk]

^ beaten too it

[mcjacko1987]

Originally Posted by outrage_uk

Good write up bud...

You need to stick "Drain gearbox oil by removing the drain plug..."
before... "Pull the passenger side driveshaft out the gearbox"... though

just edited it mate after BertieG mentioned it, good call though lol and cheers.


im hoping this will be made a sticky its asked over and over again how to do it, and with it being an expensive job at a garage hopefully it will save some people some pennies

[mcjacko1987]

Originally Posted by outrage_uk

^ beaten too it

haha

[f13sta]

nice one mate.
i've only ever used air tools cause i have them at home. but can always replace gearboxes for other people on the side (i'm a mechanic) if they are unsure and provide their own gearbox.

[mcjacko1987]

Originally Posted by f13sta

nice one mate.
i've only ever used air tools cause i have them at home. but can always replace gearboxes for other people on the side (i'm a mechanic) if they are unsure and provide their own gearbox.

i used to rely on mechanic mates about 2 weeks ago for this but took a close look at what was going on and since that took the box off twise now so thought id do this the 2nd time.
wouldnt mind doing it as a full time job though, or a bit on the side to earn some more money

[Vtrsi76]

top guide mate.....real time and effort went into that..

Gonna be very useful for me when I do my vtr to s conversion soon...

[f13sta]

Originally Posted by mcjacko1987

i used to rely on mechanic mates about 2 weeks ago for this but took a close look at what was going on and since that took the box off twise now so thought id do this the 2nd time.
wouldnt mind doing it as a full time job though, or a bit on the side to earn some more money

belive me mate you don't want to be doing it full time. unless you mean working on saxo's.

it's a terrible job to do particually when you get nothing but shitly built/designed cars in lol

[mcjacko1987]

Originally Posted by f13sta

belive me mate you don't want to be doing it full time. unless you mean working on saxo's.

it's a terrible job to do particually when you get nothing but shitly built/designed cars in lol

i mean working as a mechanic full time lol. always wanted to since iv been driving. learnt most of the stuff i know off my own back and threw mates and forums. maybe one day il try it and see how much of a stressful job it can be haha

[danny-vts]

nice guide

[mcjacko1987]

Originally Posted by danny-vts

nice guide

cheers mate

[danny-vts]

i need to do box and clutch on my gti but honestly cba lol

[mcjacko1987]

Originally Posted by danny-vts

i need to do box and clutch on my gti but honestly cba lol

haha i was like that this morning tbh. really couldn't be bothered but needed to be done.




id do a guide to fitting it back on tomorrow (if i fit the other box) but it is basically just get the box in place and connect everything back up, so working from bottom of this guide to the top lol.