cant get gearbox back in

[saxpest]

I'm changing the gearbox on my 02 bye following a guide on here, I've got the old one off but can I he'll get the new one back in. It's hitting the drivers side drive shaft stopping me lifting it in. I've removed the drivers side ball joint for that little bit more play I've undone to two nuts on the intermediate bearing and rotated the bolt heads bit it won't shift! If I can move the drive shaft back an extra 2 inch I'd be able to get the box back on.

[sulgravesax]

make sure all the bolts and clamps are undone on the intermediate shaft housing and then put a block of wood on the end and hit it with a lump hammer. obviously make sure its out of the hub end first. that's all i did on mine and eventually it came out and the gear box went back in. you can get it back in without moving the drivers side shaft but it takes time and patience and 2 pairs of hands. plus a lot of shouting and doing about.

[saxpest]

Originally Posted by sulgravesax

make sure all the bolts and clamps are undone on the intermediate shaft housing and then put a block of wood on the end and hit it with a lump hammer. obviously make sure its out of the hub end first. that's all i did on mine and eventually it came out and the gear box went back in. you can get it back in without moving the drivers side shaft but it takes time and patience and 2 pairs of hands. plus a lot of shouting and doing about.

Yeah I'm by myself so lots of shouting loads of bruising and I'm no further forward lol, the Haynes said there were only 2 bolts on the shaft housing to take out push the bolt through and turn them, it should move but it's stuck fast

[iSlayeR]

Remove the complete driveshaft out of the way buddy, very difficult to line both splines up

[Ali123]

Very awkward getting the box back in with the shaft still in, not too awkward on a ramp like! But on the floor it's a reet cunt, just remove the whole shaft dude

[saxpest]

Originally Posted by Ali123

Very awkward getting the box back in with the shaft still in, not too awkward on a ramp like! But on the floor it's a reet cunt, just remove the whole shaft dude

I'm trying to but I can't get the shaft out the intermediate bearing, I've took the two bolts off, pushed the bolts back and rotated the heads, even with a chock of wood and a hammer it's not moving.

[iSlayeR]

Originally Posted by saxpest

I'm trying to but I can't get the shaft out the intermediate bearing, I've took the two bolts off, pushed the bolts back and rotated the heads, even with a chock of wood and a hammer it's not moving.

Yep, can be a right arse to get out sometimes, remove the nuts and bolts altogether, then I try and use a bar and hammer and give it a tap

[Gandi699]

Getting the box off with the R/H shaft is possible. Refitting? Forget it, I tried it and didnt get anywhere so just removed the bearing as I was being lazy but it ended up costing me more time. Easier to take the bracket for the intermediate bearing off the block if you have problems getting the bearing out the carrier

[saxpest]

Originally Posted by Gandi699

Getting the box off with the R/H shaft is possible. Refitting? Forget it, I tried it and didnt get anywhere so just removed the bearing as I was being lazy but it ended up costing me more time. Easier to take the bracket for the intermediate bearing off the block if you have problems getting the bearing out the carrier

Going to take the bracket off tomorrow and try again, cheers.

[johnnyg_vts]

I changed my VTS box and clutch with both shafts still in the hubs with the hub nuts still insitu. Left the ball joint in too, took off one end of each drop link for a bit of extra wiggle room. I did it on my back, on my own. It's difficult but not impossible. Get the box lined up and on, then put the 4 bolts in and next pull the roadwheel outwards and get the shaft back in the box. Just be careful not to dislodge your gearbox/ driveshaft seals.

[D4MJT]

If you're still stuck with this mate, just unbolt the whole intermediate bearing carrier from the back of the engine rather than trying to get the shaft out of it, assuming you have the shaft free of the hub, you can take it out from under the car and then work on getting the shaft out of it away from the car, bit more room etc. I've done this before when the shaft has seized into the bearing housing.

[saxpest]

Originally Posted by D4MJT

If you're still stuck with this mate, just unbolt the whole intermediate bearing carrier from the back of the engine rather than trying to get the shaft out of it, assuming you have the shaft free of the hub, you can take it out from under the car and then work on getting the shaft out of it away from the car, bit more room etc. I've done this before when the shaft has seized into the bearing housing.

Both hub nuts still on,I'm following the guide off here, if I unbolt the carrier bracket I'll have enough play to pull the shaft back that extra inch that I need to get it back in, also is it worth regreasing the cv joints while I'm playing with the driveshafts.

[Gandi699]

Originally Posted by johnnyg_vts

I changed my VTS box and clutch with both shafts still in the hubs with the hub nuts still insitu. Left the ball joint in too, took off one end of each drop link for a bit of extra wiggle room. I did it on my back, on my own. It's difficult but not impossible. Get the box lined up and on, then put the 4 bolts in and next pull the roadwheel outwards and get the shaft back in the box. Just be careful not to dislodge your gearbox/ driveshaft seals.

Sounds like a fair bit of manhandling that!


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[saxpest]

Gearbox is back in and back on the road, thanks for the help all.
Only thing I've noticed is a knock when I move the gearstick to the left, but I'll have a look when it's light.

[Maxikep]

Thanks Gary - if it's only a pump I would be VERY happy.
Gearbox iues are always pricey. I am sure it is oil related.
I'll let you know what I find.
Richard

[Kylus1986]

Originally Posted by Gandi699

Getting the box off with the R/H shaft is possible. Refitting? Forget it, I tried it and didnt get anywhere so just removed the bearing as I was being lazy but it ended up costing me more time. Easier to take the bracket for the intermediate bearing off the block if you have problems getting the bearing out the carrier

It can be done quite easily on the ground with the drivers side shaft in. Does take a lot of practice though. I can now get a box back in and built up in less than half an hour, but I've done it a few times now. Does completely destroy your back though if you are foing it on your own

[Gandi699]

I found it's difficult to get the shaft back in the diff hole. rather than wreck your back spend 15 mins getting the old shaft out. I'd not even taken the offside strut off when i was doing it however so the shaft didn't have much give


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[axsaxoman]

only an idiot wuld try to remove +refit a g/box with shafts still fitted to car
good recipe for damaging drive shafts and seals
its another 10mins to remove o/s shaft

[Gandi699]

if you've removed the passenger side shaft and strut, you can slide the box off the O/S shaft quite easily without damaging the seal which really you should change anyway if they are old for peace of mind. Its getting it back on which would be extremely difficult so dont bother to even attempt it

[Kylus1986]

Originally Posted by axsaxoman

only an idiot wuld try to remove +refit a g/box with shafts still fitted to car
good recipe for damaging drive shafts and seals
its another 10mins to remove o/s shaft

Done it plenty of times with no issue with shafts or seals.

If it seems stupid but it works it isn't stupid