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Gearbox Removal - help!

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02 Dec 2017 18:59 #186946 by ryan28
Hi all,

So I thought I'd have a go at swapping my failing gearbox for another one.

I've never done anything like this before but I've been following the great guide on here for changing the clutch.

Currently stuck on actually getting the gearbox off the lugs, I'm able to stuck a screwdriver in the gap and level it apart but I can't get it far enough to get it to drop down. I've left on the shifter mechanism on the top however the transfer box and all the props have been removed so I can't see anything restricting it.

Anyone got any advice?



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02 Dec 2017 19:09 #186947 by safari
Replied by safari on topic Gearbox Removal - help!
you have to remove everything even shifter and supposed you removed the mounting on the bottom

if u worry u die if u dont worry u still die so why worry

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02 Dec 2017 19:12 #186948 by ryan28
Replied by ryan28 on topic Gearbox Removal - help!
Ok, I'll remove the shifter as well in that case....I didn't bother because it looked like a pain in the ass!

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02 Dec 2017 19:41 #186949 by facade
Replied by facade on topic Gearbox Removal - help!
I had to undo the engine mounts on the chassis and draw the engine forwards as well as taking the clutch apart whilst on the car to get it off.
When it was out I cut 1/2" off the flat plate on the chassis that the rear mount sits on to get it back with the clutch on.

The remote and the metal bracket it sits on have to come off the back of the gearbox for sure.

Very annoying as it looks as if it will come out all the time, but it just won't quite......

If it suddenly breaks, go back to the last thing that you did before it broke and start looking there :)

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02 Dec 2017 19:43 #186950 by ryan28
Replied by ryan28 on topic Gearbox Removal - help!
Thanks, I'll give that a go tomorrow. What a ball ache, thought these cars are simple to work on!

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02 Dec 2017 20:12 #186953 by TomDK
Replied by TomDK on topic Gearbox Removal - help!
Perhaps consider doing something like this?
Takes only a little more than an hour to remove the gearbox :)


+3" Trail Master. Fox 8.0" R/R shocks. ORA HD winchbumper. Warn M8274 Ox-motor + Hellfire gears, Delta-Tek mainshaft and freespool, overvolted. 33/9.5 R16 Silverstone Extreme. 5.14:1 ratio SJ transferbox in RW cradle. OMP rollcage.
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03 Dec 2017 17:41 #186974 by safari
Replied by safari on topic Gearbox Removal - help!
never thought of that very good idea

if u worry u die if u dont worry u still die so why worry

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03 Dec 2017 19:26 #186978 by mlines
Replied by mlines on topic Gearbox Removal - help!
Its a horrible job that I have done once and never again.

Its into my friendly workshop tomorrow for a clutch change and MOT for BigJimny.

Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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03 Dec 2017 20:35 #186980 by TomDK
Replied by TomDK on topic Gearbox Removal - help!
That's why I did the removable crossmember.
With access to a welder. It took less time to make this, than to start doing it the normal way.

+3" Trail Master. Fox 8.0" R/R shocks. ORA HD winchbumper. Warn M8274 Ox-motor + Hellfire gears, Delta-Tek mainshaft and freespool, overvolted. 33/9.5 R16 Silverstone Extreme. 5.14:1 ratio SJ transferbox in RW cradle. OMP rollcage.

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04 Dec 2017 11:46 #187009 by mickt
Replied by mickt on topic Gearbox Removal - help!
That is why when I did my daughters clutch I removed the engine even though the forum all said it only takes an hour! The only problem I had was actually removing all the bellhousing bolts as every one was tighter than tight and access is not easy but that part was a step that had to be done on either option.

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09 Dec 2017 13:07 #187213 by ryan28
Replied by ryan28 on topic Gearbox Removal - help!
Well....progress. I've removed the gear selection mechanism from the back and she's free!

The following pictures may be very familiar to some of you....I can't get the sodding thing out.



I'm working under the car with it on wheel ramps so laying on my back it's quite hard to maneuver it, without worrying too much about it coming down on me! The next step I can think of is to tip the engine forward a bit with some straps just to get the little extra room needed.
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09 Dec 2017 13:36 - 09 Dec 2017 16:22 #187219 by mickt
Replied by mickt on topic Gearbox Removal - help!
Yes, I had to pull the engine forward using ratchet straps when I did it years ago

When I changed the clutch on Tuesday it was simple. I sat in my lounge watching TV and drinking coffee and when the phone rang it was done.
Last edit: 09 Dec 2017 16:22 by mlines.

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