Gear box removal hours

[ukkid35]

I could never earn money working on cars - I am glacially slow at any job I attempt

Sadly, even with lots of experience of removing the gear box, usually in order to remove the heads, it still takes me forever

This time I have spent exactly 7 hours to get to the point where I can remove the box

I admit I don't use the WSM procedure of tying/prying the exhaust manifolds and spinning the T5WC so as to drop it between them

Even if I could extract it that way (which I couldn't) there is no way I could reinstall it with manifolds in place

I'm sure it would be slightly less impossible with access to a lift, but even though I've seen it extracted with axle stands, I still don't believe it could be reinstalled


How do you do this job, and how long does it take you?


PS - reason for removal is failure to replace the clutch release bearing just a few weeks earlier resulting in a very noisy bearing

[CerbWill]

Jack car onto 4 axle stands.
Remove chassis brace.
Split exhaust at cats and remove.
Remove heatshield.
Remove propshaft.
Remove throttles and fuel rail (4.2).
Remove starter motor.
Remove gear shifter from box.
Disconnect reverse switch wiring.
Remove lambda sensors from exhaust.
Unbolt gearbox from clutch housing.
Unbolt clutch housing from engine.

With standard manifolds:
Lift gearbox back down transmission tunnel.
Drop clutch housing out.
Slide gearbox forwards and out under the engine.

Maybe 2hrs 30.

With ACT Performance Manifolds:
Lift gearbox back down transmission tunnel.
Discover clutch housing doesnt come out the gap between the manifolds.
Wonder which fking idiot welded them so theres not enough clearance and they hit the gearbox unless spaced out at the manifold>cat join.
Try to remove lower halves of the manifolds.
Realise removing the OS lower section doesnt give enough clearance.
Try to remove NS lower section.
Wonder why it's not split as per the OS to make this job easier.
Realise you cant because 2 sets of studs are set at 90 degrees to each other so prevent all movement even with nuts removed.
Realise this means removing the entirety of the NS manifold.
Swear profusely at the fking idiot who took a great concept and half arsed the design.
Tea/beer and think it through.
Remove 1 set of studs.
Remove NS manifold lower section.
Remove clutch housing.
Remove gearbox.
Wonder what sort of idiot would spend £1500 on shiny exhaust manifolds.

Hours: God knows, many hours have passed in a blind rage.

[itsallyellow]

At most 30 minutes,

Jack up car
Remove chassis brace
4 propshaft bolts
4 Bell housing bolts
2 gear lever bolts

Having side exit exhaust helps a lot!

We have replaced a gearbox in between quali and a race before in less than an hour

Mike

[Mr Cerbera]

Paul, I am just finishing my second year doing my 100K service so you are a speed demon compared to me.

Now, it's true that I am a slave to The Real World
but
I am surprised at your post, having seen your brilliant disassembly vids in the past.

So you've followed MadMark's directions for disconnecting the drive up to the Bellhousing.

Now, I've read articles saying that one side of the exhaust manifolds is much easier to access than the other.
(from memory I think it was the passenger's but I may be wrong)

Unbolt that and then
the gearbox will land on your eye !

Following that, you've got the guide in the 'How to' thread links to help you disassemble

Edited by Mr Cerbera on Friday 12th June 23:05

[Mr Cerbera]