Changing A Gearbox / Rear Diff

[emmo]

People

I am changing my 'box and rear diff next Thursday. I will be doing the work along with a colleague of mine's who's a decent mechanic.

Anyway, I am in need of some idea where to start to get the box out of a classic. I know Dazzler has just gone through this so perhaps he might be able to chip in. Anything we need to watch out for? Anything that, having done it once, you thought I must remember that for next time (although hoping there won't be a next time!!)

Any assistance gratefully received.

Many thanks in anticipation

Martin

[dazzlers82]

its pretty straight forward mate just remember that on the passenger side there is an allen key bung you need to remove then fit a 6mm bolt in the whole it could be 8mm an pull the release bearing pivot shaft out the side of the box also the driveshafts have roll pins in all i done was got the wheels hanging undone one wishbone bolt either side an the driveshafts will pull off other than that its heavy so get a dcent jack to hold it up an get the car as high as you can in the air as for the diff ill be removing that once i get my box saturday an fitted next week so you may be able to tell me by then

it was the first box i had removed from a scooby an it took me about 1hr 30 an i had to chisel off starter bolts as had been rounded previously

[Baz69birds]

took my BUSTED/SMASHED/HARDLY DRIVE ABLE,

Car & box to be fixed @ API well

loverly job,

NEW BOX, CLUCTH, FLYWHEEL,

Just now £1,400 out of pocket..

Looks like may have to sell even more stuff on e-bay.

[dazzlers82]

what was wrong with it baz i picked up my new ppg box yesterday £1500 an diff

[Baz69birds]

Clucth was SEMI O.K but he suggested change it anyway,

Flywheel was CRACKED... he said Change it,

As for the GEARBOX...

dont know, BUT the SMELL & SOUND of all the nuts & bolts in the box just being rattled around was unbarable

Edited April 13, 2008 by baz69birds

[dazzlers82]

did they not take it apart an have a look for you ????

[Baz69birds]

He took it for a test drive drove up the ramp & came back... didnt get to the main road.

took the old box off & skipped it (apparently)

[dazzlers82]

mmmm i did not hear it but it would been worth finding out as may only been a bearing or somethin small ??????

[Montythegod]

People

I am changing my 'box and rear diff next Thursday. I will be doing the work along with a colleague of mine's who's a decent mechanic.

Anyway, I am in need of some idea where to start to get the box out of a classic. I know Dazzler has just gone through this so perhaps he might be able to chip in. Anything we need to watch out for? Anything that, having done it once, you thought I must remember that for next time (although hoping there won't be a next time!!)

Any assistance gratefully received.

Many thanks in anticipation

Martin

If you are doing it on the drive.. get it as far up in the air as possible..... done mine twice. although second time I had to make way for HOL under the car ,,lol

Intercooler, starter motor will have to be removed, as well as propshaft. front cv joints have pins in that will need tapping out before you can disconnect them.. and remember they are offset when you try and push the pins back in ensure the holes are aligned.

Rememeber there are different gearboxes,,, As mine is a 98 classic I bought a 99 box and we had to modify as few things to make it fit as follows :

Removed locating pins

Starter motor bolts in differently, enlarged hole in starter and tapped the gearbox casing to accept a larger bolt

Swapped over gearbox and speed sensors (electronic in mine)

If you got a lift and a hand,, then about 4 hours labour..... on a drive 6 hours,,lol

Cant comment on the diff, but will probably be doing that soon as I have blown 3rd in my box at the moment and need to go through it all again

Looking about for a cheep 6 spd setup

[dazzlers82]

If you are doing it on the drive.. get it as far up in the air as possible..... done mine twice. although second time I had to make way for HOL under the car ,,lol

Intercooler, starter motor will have to be removed, as well as propshaft. front cv joints have pins in that will need tapping out before you can disconnect them.. and remember they are offset when you try and push the pins back in ensure the holes are aligned.

Rememeber there are different gearboxes,,, As mine is a 98 classic I bought a 99 box and we had to modify as few things to make it fit as follows :

Removed locating pins

Starter motor bolts in differently, enlarged hole in starter and tapped the gearbox casing to accept a larger bolt

Swapped over gearbox and speed sensors (electronic in mine)

If you got a lift and a hand,, then about 4 hours labour..... on a drive 6 hours,,lol

Cant comment on the diff, but will probably be doing that soon as I have blown 3rd in my box at the moment and need to go through it all again

Looking about for a cheep 6 spd setup

go ppg mate 6 speed to heavy

[emmo]

its pretty straight forward mate just remember that on the passenger side there is an allen key bung you need to remove then fit a 6mm bolt in the whole it could be 8mm an pull the release bearing pivot shaft out the side of the box also the driveshafts have roll pins in all i done was got the wheels hanging undone one wishbone bolt either side an the driveshafts will pull off other than that its heavy so get a dcent jack to hold it up an get the car as high as you can in the air as for the diff ill be removing that once i get my box saturday an fitted next week so you may be able to tell me by then

it was the first box i had removed from a scooby an it took me about 1hr 30 an i had to chisel off starter bolts as had been rounded previously

Finally got a couple of days today and tomorrow to change my 'box so we started this morning. Touch wood, everything seems to be going ok and the new box is in. Everything came off ok and there were no major crisis. The biggest pain seemed to be relocating the new 'box because the splines were obviously not aligned properly and you obviously can't see them once the bell housing is virtually butted to the engine. The prop shaft and exhaust need to be put back and the gear level linkage needs fitting. Once that's done, we will then work on the diff.

Having been kind of carless for about 6 weeks, I will be so pleased to have her back to full strength again.

I am intrigued by Dazzlers figure of about £1,500 for a PPG box - figures I have been looking at have been around £1,000 more than that. Where did you get your PPG box, mate?

[dazzlers82]

Finally got a couple of days today and tomorrow to change my 'box so we started this morning. Touch wood, everything seems to be going ok and the new box is in. Everything came off ok and there were no major crisis. The biggest pain seemed to be relocating the new 'box because the splines were obviously not aligned properly and you obviously can't see them once the bell housing is virtually butted to the engine. The prop shaft and exhaust need to be put back and the gear level linkage needs fitting. Once that's done, we will then work on the diff.

Having been kind of carless for about 6 weeks, I will be so pleased to have her back to full strength again.

I am intrigued by Dazzlers figure of about £1,500 for a PPG box - figures I have been looking at have been around £1,000 more than that. Where did you get your PPG box, mate?

got it 2nd hand mate an the diff will take you all of about 30 minutes to change it is that simple

[granby]

I am intrigued by Dazzlers figure of about £1,500 for a PPG box - figures I have been looking at have been around £1,000 more than that. Where did you get your PPG box, mate?

He was a lucky b******* getting a bargain like that

Emmo glad it's all coming to together now, hope you don't have any last minute surprises

[emmo]

Finally, after much blood sweat and tears (well, two out of three anyway) success.

The gearbox is in, the diff is in and all works well. There are a few unusual noises but I'm gonna give it a few days to run it in, then check everything over again and make sure everything is tight and sorted.

Many thanks to those who've offered advice when requested and also for eurosti for making the trip over from Germany solely to bring me a 'box and diff! Top man!

[dazzlers82]

Finally, after much blood sweat and tears (well, two out of three anyway) success.

The gearbox is in, the diff is in and all works well. There are a few unusual noises but I'm gonna give it a few days to run it in, then check everything over again and make sure everything is tight and sorted.

Many thanks to those who've offered advice when requested and also for eurosti for making the trip over from Germany solely to bring me a 'box and diff! Top man!

nice one mate