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slobberingant

306 Gearbox Trouble

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slobberingant

Hi all,

 

I'm having some compatibility issues with installing a 306 gearbox in my 205 gti.

Its a BE3 gearbox and a late 205 gti so I thought that it would be a pretty straightforward swap.

But after mating it to the engine I realised that the gear linkages don't fit.

My old gearbox had the linkage lever like this:

gearboxswap1.th.jpg

The linkage lever is one flat plate.

 

My new gearbox has a bend in the linkage lever so the original linkages no longer fit.

Does anybody know of any practical method to connect the linkages to the new gearbox?

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pug_ham

Carefully removed the double roll pin which holds the lever to the gearbox & swap them over from old 205 BE3 to the new box but make sure the shaft from inside the gearbox doesn't drop or you can loose some gears when you reconnect it.

 

Check you can still get all six gears (1-5 & reverse) before you fit it into the car.

 

Graham.

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slobberingant
Carefully removed the double roll pin which holds the lever to the gearbox & swap them over from old 205 BE3 to the new box but make sure the shaft from inside the gearbox doesn't drop or you can loose some gears when you reconnect it.

 

Check you can still get all six gears (1-5 & reverse) before you fit it into the car.

 

Graham.

 

Wow 4 minutes! Thanks for the answer. I will give this a shot!

I was thinking of getting a custom linkage made up but this seems a lot easier.

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madspikes

Been there done than, made a hash of it!!! But got there in the end!

 

If it does drop down and you cant get all gears, dont worry all is not lost! Just pull the lever off again and using a mixture of pushing it down slightly, lifting it up and rotating it back and forth will hook it all back up. Sometimes is slots back together easily, and sometimes it takes a while.

 

Might be worth checking the clutch fork as well.... to check it suites the bearing your going to use.

 

Mad.

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pug_ham

You could use a strong magnet to hold the shaft in place but I've done a few with the box in fifth gear & nothing more without issue.

 

If it does fall all you need to do at most to put it back into the right place is remove the diff, you can feel the link with your finger & put it back in the right place.

 

Graham.

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foreigner

apparently there is grove when you pull it up and you can insert circlip in it to hold it in place ,

 

I did drop the shaft in too and took me another 3 hours to swap the box for another one with modified lever, neighbours were happy when I finished at 11 pm on the road.

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slobberingant

Thanks for your replies! I will definanately try my best to avoid dropping the shaft into the gearbox!

Madspikes, yep i've had to change the clutch fork as well. Also, the reverse gear selector is different and the speedo housing is electric so I will have to change that also.

Another thing is my 205 has aircon so the oil filter was remotely fitted via an external body onto the gearbox but the 306 gearbox doesn't have the bolt holes there to attach the remote body to. I was thinking of removing the whole remote filter assembly and attaching the oil filter directly to the engine (like in most non-aircon models) but then the air con system blocks access to the oil filter. Being in Australia I would prefer to keep my aircon :) . Does anybody have any ideas about what I can do here?

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pug_ham

Could you make a bracket to mount the remote filter to or drill & tap the new gearbox casing before you fit it?

 

Use the speedo drive etc from your old 205 gearbox.

 

Whats different about the reverse gear linkage?

 

Graham.

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slobberingant
Could you make a bracket to mount the remote filter to or drill & tap the new gearbox casing before you fit it?

 

Use the speedo drive etc from your old 205 gearbox.

 

Whats different about the reverse gear linkage?

 

Graham.

 

Hmmm I'll have a look around to see where I could mount a bracket. I can't drill into the gearbox where the body used to connect as that surface isn't flat on the 306 gearbox. Mounting the filter anywhere else would involve extending or shortening the oil hoses which I would like to avoid cause i'm lazy. I was hoping someone has had some experience with it before but its no big deal. I'll post up what I find to be the best solution.

 

I didn't mean reverse gear linkage I meant reverse sensor plug. My bad. The 306 reverse sensor plug is different to the reverse sensor plug in my 205. I just need to find a deep enough socket to remove it and replace with my original one. Does anybody know its size? 21mm or 22mm??

 

I managed to get my linkage changed. Thanks for the advice! I held the shaft with a piece of string to stop it falling it out then just carefully replaced the linkage lever and hammered in new roll pins. I did this all with the gearbox on the car!!! Definitely not easy but possible for the record :lol:

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welshpug

beware of different length reverse light switches, you may find that you need to keep the one you have there and change the plug :lol:

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pug_ham

Aren't there any other threaded holes in the casing you could use to mount a bracket to hold the filter body in the same place or soething to hold it to the back of the front valance near the radiator cowling?

 

Be3 reverse switch is 22mm.

 

Graham.

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slobberingant
beware of different length reverse light switches, you may find that you need to keep the one you have there and change the plug :)

 

OOOOOO you've just opened a whole new can of beans :) . Are there compatibility issues between reverse light switches? I wasn't aware of this.

How can I find out if the reverse light switches are interchangable?

 

Aren't there any other threaded holes in the casing you could use to mount a bracket to hold the filter body in the same place or soething to hold it to the back of the front valance near the radiator cowling?

 

Be3 reverse switch is 22mm.

 

Yes there are a few holes running along the lip of the gearbox. A few are threaded and some are just holes. I think a bracket with a 90 degree angle mounted on one of these lips would be best. When I get my camera back I will post up some pics. Thanks for the switch bolt size. I now have to work out if the reverse light switches are compatible before I make any changes. :)

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slobberingant

I've done a search on the differences between reverse light switches in different gearboxes and it seems that the only difference is between BE1 and BE3 gearboxes. The plug on my 306 BE3 gearbox is different to my 205 BE3. Are there differences between BE3 reverse switches? What would be a better option, to swap the switches over from my old gearbox or to find a plug off a 306 and wire that into my 205?

 

Thanks in advance.

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welshpug

just take the switch out and measure it would be the quickest way to see if it'll cause any issues :)

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