Replacing Be1 Gearbox With Be3

[Guest jon-the-sticks]

Hi. I'm about to replace the BE1 gearbox in my '87 1.9 with a BE3 and was wondering if I've forgotten anything before I start. Things I have so far are...

 

The gearbox

New clutch

Later clutch pedal / cable

Grommet to seal reverse cable bulkhead hole

New driveshaft oil seals

Gearbox oil

Sealing washer for fill plug (I think - is this just a copper one, same as the sump?)

 

Anything else?

 

I was also wondering about changing the linkage rods (the ones with knuckle joints on the ends) but the dealer suggested that the BE1 items are different from BE3 so now I'm wondering if I may be forced to change them and possibly the whole linkage? Can anyone help?

 

Jon

[marksorrento205 80]

Dont think your far off mate. If your gonna change the gear rods get a set from Miles on here!!

[sub205 5]

i converted my clutch cable with a thread bush. i mounted the bush over the thread of the old cable and put another thread rod on on it.

 

CABLE]------====-------|

- - - - - - - - bush - rod

 

 

works fine since 100000km now ;-)

Edited March 23, 2010 by sub205

[Baz 421]

Gear rods are the same.

 

Release bearing is actually the only different clutch part, friction and cover plates are the same.

[danny56712 1]

so besides replacing parts, all is needed is a different release bearing clutch pedal and cable

[ifcho 0]

actually there are clutch cables that fit the old pedal and the new gearbox. You just have to scan the catalogues.

[danny56712 1]

any idea where to get them

[ifcho 0]

In Bulgaria Yes, in Ireland No

[Guest jon-the-sticks]

Cheers guys. What's special about the gear rods from Miles and can someone help me with his email?

[Miles 331 1 Cars]

The cable you cannot buy anymore unless you find a old one on Ebay.

 

So it's easier to get the clutch pedal, From any BE boxed 205 or 309 not just GTi's with the cable, You might have to make the hole in the pedal box round but thats about it

 

Full details of my Rods are inthe group buy section or via my Ebay link

[ifcho 0]

I think that the TU box pedals are the same as well.

[danny56712 1]

thanks a million guys help appreciated, oh and those input shaft bearings i see are recomended is there much hassle in fitting these

[Guest jon-the-sticks]

Got all this done in the end. A whole load of work but not too bad except the clutch cable change. I couldn't for the life of me work out how to get the old cable out since the new one I had looked like it just pushed in. After hours of swearing, I realised that it had a different fitting which wasn't obvious because it's so tucked away under the servo. I had to get some mole grips on it and twist it, then it came out no problem. That also meant that the new one wouldn't fit straight in because the hole in the bulkhead was too small. I think this is what Miles was alluding to in one of his comments. Eventually, I rounded the hole off a bit with a circular file (the earlier fitting's hole is not circular - rather it has two cutouts on either side) then cut down the grommit on the new cable to just leave the larger thicker section. The cable then fitted through. Given that the whole thing is under tension, I don't think having part of the grommit missing is really a problem.

 

Turns out the flywheel was knackered too. Looked like the starter had been mashing it so there was a patch where the teeth were all chewed up. Managed to get another one (thanks Dan!), fitted a new starter (modern ones seem to be about half the size and weight of the original), and now it cranks much better than it used to.

 

Thanks everyone for your help.

 

Jon