Help Please, Driveshaft Wont Go In Gearbox

[layton1985 5]

Hi I am having a serious problem with my gearbox, serious in the fact that it's really annoying me and I won't be able to use the car for a while untill this is resolved here is a break down of the situation,

 

I bought the 309 gti auto, wich has been converted to manual gearbox,

 

I wanted to convert it to a v6 but had to work away so put it back on wheels and left it old shafts got binned,

 

I have just put a 406 sri turbo engine in, I bought two new driveshafts brand new, the short side fit perfect, the long shaft will not go into the gearbox and engage the splines for the love of money,

 

I have tried at different angles, turning the other driveshaft whilst pushing it in, putting it in gear and turning the driveshaft whilst pushing it in, nothing!!

 

when I pull it out a midges and shove it, it makes a clunking noises - metal against metal.

 

Has anyone had this problem before? I am not sure what gearbox is on the car? How do I find out? If there are numbers can someone post the numbers to the 1.6, 1.9 or desiel box's for me to cross reference please?

 

has something inside the gearbox moved it doesn't look like it, it's very clear looking inside all turns feels smooth on fingers

 

I may have to buy another gearbox but don't like being beaten by a problem also I may come accross this again in the future or someonelse may need help?

 

Tanks Lee

[welshpug 1,666]

which gearbox do you have in it?

 

you need to match the intermediate driveshaft housing to the gearbox.

[layton1985 5]

not sure what the gearbox is do you know any numbers I can compare it to? I think off top of my head there are 24 splines at gearbox end and 25 splines at the hub end

 

thanks Lee

Edited December 6, 2011 by layton1985

[layton1985 5]

The short driveshaft has gone in fine with no problems and that has the same end as the long shaft

[welshpug 1,666]

take a picture, if it still has the original 8v turbo intermediate driveshaft bearing carrier and a BE gearbox it wont fit as its made for an ME or ML gearbox which has the diff at a different angle.

[layton1985 5]

Ahh that could be it, the bottom enfine mount/shaft bearing carrier is the 2.0 turbo mount i didn't know i had to change that im sure my mate left his standard on his?? i will take it off asap and put the driveahaft in on its own thanks mate your a star

[welshpug 1,666]

you cant just remove it, you need to use one from an XU engine that used a BE box.

[layton1985 5]

Thanks mate I changed the bottom mount and the driveshaft went straight in, it's nearly complete now I have the main wires connected to run the car, just got a few left over that I am unsure about like the vss cable?? I have heard that this can be wired in and improves fuel consumption? If that's true I want that in deffo,

 

got it turning over today on the starter, fuel filling a bottle aswell just don't know what people to do get the old fuel lines onto the turbo fuel rail? my fuel lines are way to thin and the return line to short, hpefully there are reduces resistant to petrol that I can buy, got to find first though.

 

Thanks again Lee