gearbox removal

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stifler1603

New Member
how do you remove the gearbox with the engine still in the car, and what is the easiest way of getting the gearbox bolted back onto the engine? i'm tired of removing the entire engine just to change a clutch
 
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MarkTurbo

Well-Known Member
Basically remove all the driveshafts etc. To remove the box with the engine in you'll need to take the end cover off the transfer box and pull the diff out (don't lose the shims) once thats done just take the gearbox engine mounts off and lower that side down and you'll be able to pull the box off like you would if it was a Fwd car leaving the transfer box on the back of the engine.

Thats probably made it sound simpler than it is and I've probably forgotten something but its late and I'm tired :lol:
 
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bevis

Member
Would be easier if u remove transferase an gearbox together...
Let go all drive shafts, all brackets holding it to de block and all mounts except de one on driver side.. Loosen and remove gearbox bolts and leave the 2 top 17mm bolts. Then u could ease down gearbox an put a jack stand or something under oil pan to support engine..
With jack under gearbox, remove the last two 17mm gearbox bolts at the top then jus simply pull gear box off... Coming off is de easy part an could be done alone but goin back up is same in reverse but tricky an you'll need help
 
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Gtirjoeynew

Member
I burred a couple mil off of one of the transfer case 'cooling fins' and i can slide my transfer box straight off, which inturn makes the clutch a 45 min job:-D
 
alphadrex

alphadrex

Member
Gtirjoeynew said:
I burred a couple mil off of one of the transfer case 'cooling fins' and i can slide my transfer box straight off, which inturn makes the clutch a 45 min job:-D
Click to expand...
Hey,

I know this is a thread from the dead, but I'm looking to do my clutch and was wondering if there were any pics floating around of this mod... This would be revolutionary for the rest of us. How does this mod change the procedure (i.e. what steps are no longer required or are now added?)

Anybody got any other critical tips would be greatly appreciated as well. I know I'm swapping the release bearing and pilot bushing while I'm in there, but is there anything else I should look at doing? Please advise. Thanks to all in advance for your help.

alphadrex
 
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Ally

Member
Gtirjoeynew said:
I burred a couple mil off of one of the transfer case 'cooling fins' and i can slide my transfer box straight off, which inturn makes the clutch a 45 min job:-D
Click to expand...
If I find one close and see what he means i will picture it before and after to show you guys
 
steven-c

steven-c

Member
first time I did a gtir clutch left the transfer and gearbox in the car and swung the gearbox down out of the way.. took longer than dropping the engine in and out... Just drop the lot that's the way they are designed quick and easy to remove as one... end of the day they are a rally car... designed to be done easy in the paddock.
 
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murty

Member
personally i dont like the idea of shaving any thing off for fear of weakening the case, i have dropped the gearbox with the engine in situ must be over 10 times now, i have also dropped engine and gear box together countless times as well. both have there merits, me personally, as the engine been in and out recently i am concerned with things getting stressed from wires pulling and breaking to plugs getting brittle, the power steering pipes and vac pipes getting stressed.

where as just to do the gear box you only got to unplug reverse, speedo and live to the starter and battery.

anyway here is how i do it.

Gear box removal with engine in situ

1, crack off the wheel nuts
2, remove boost pipes disconnect battery
3, support engine
4, un plug reverse
5, drain gear oil from gearbox and transfer (hit the gear box drain plug with a hammer couple of times to help loosen it) do not over tighten putting it back on.
6, remove exhaust
7, disconnect prop and gear linkage
8, remove wheels, propshafts
9, remove front nearside engine bracket
10, remove 2 bolts and nut to drop rear nearside mount
11, remove gearlinkage brace
12, remove nearside mount
13, remove oil filter
14, disconnect speedo
15, disconnect starter and remove
16, disconnect clutch
17, remove far side cast bracket above the right hand side drive shaft 4 bolts and the cast bracket below the starter 6 bolts
18, disconnect top gear box sway bar mount
19, attach transfer support, a jack if your on the floor i use a metal bar that goes under the front cross member and anti roll bar.
20, remove 7 transfer bolts
20, remove 7 gearbox bolts
 
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