Help, Can't Get Gearbox Back On!

[soundguy 13]

(Engine is out, BE3 box on XU)

 

I need your help, please!

 

Have loosened the gearbox bolts, pulled the case away slightly from the rest of the housing, removed/cleaned the magnet and some metal debris before realising I've bitten off more than I can chew.

 

Magnet back in but now I can't get the box back on. No amount of wriggling, swearing, asking nicely, moving the gear selector arms/levers/whatever they're called to different positions in the hope of making things move back into place.

 

What do I need to do to be able to make the casing faces mate up again? I just can't get things to drop into position to let it slide back into place...

[yeti-dj 7]

hello,

 

moving the gear selectors around isn't going to help as this only moves the gears inside the box

 

the only part you need to worry about lining up is the shaft from the engine into the clutch, try turning the box clockwise then anti clockwise to see if that helps line up the input splines

 

also did u take the starter off before unbolting the box? if not take this off

 

good luck

[soundguy 13]

No, I didn't take the starter off - got a new one ready to to go on anyway, will also try turning the box to match the splines. Thanks!

[omega 82]

maybe its not pulling in square

get some long bolts and pull the two together

[mikeyd 13]

did you remove offside driveshaft ? if not then its probably caught on the diff / oilseal /casing + using longer bolts to" pull it in" will maybe f**k up something if its not lined up properly !

[soundguy 13]

Driveshafts off - hopefully just the starter

[welshpug 1,661]

I think you need to take the box off and re-assemble it properly, it will need sealant in the join.

[scbond 15 1 Cars]

Haven't done it on a 205 but if you're trying to do it while hold the box I always found getting a trolley jack under it, lifting it into the rough position by hand and then jacking it up to hold it in place so you can use both hands to mate it up properly making fine adjustments.

[Tom Fenton 1,542]

Most of you have missed the point, Welsh has got it though.

The op isn't trying to get the box back on the engine, he has split the gearbox itself in half. The mention of a magnet is the giveaway.

As welsh says it needs to come properly to bits now to clean and reseal the casing halves as otherwise it will just piss oil everywhere. You will need a GOOD set of pin punches to dismantle the selector mechanism.

[soundguy 13]

Oh ****. Stripping/dismantling a gearbox is well outside my comfort zone. I need a mobile mechanic as per my other post. Anyone know anyone in the Newcastle area?

Edited June 17, 2015 by soundguy

[Tom Fenton 1,542]

I think the task in hand will be beyond most mobile mechanics, plus you'd want a decent bench to dismantle and rebuild a gearbox on anyway.

[mrfirepro 127 1 Cars]

do a google search I found two really good guides for rebuilding the GB, this was one of them http://www.eastment.net/BE3%20Gearbox%20Strip.htm

 

the other one was the most helpful and detailed, I'm sure others here will point you in the right direction

[johniban 59 1 Cars]

How did you get on? and why have you removed the case? its not too hard to do what needs to be done, but you do need it out on a bench 5th gear side up so you can seal the joint

[jackherer 543]

do a google search I found two really good guides for rebuilding the GB, this was one of them http://www.eastment.net/BE3%20Gearbox%20Strip.htm

 

That guide was made by one of our members, Jim21070, I gave him the gearbox he used to write it.

[welshpug 1,661]

ahh! I met Jim a while back when he bought some V6 bits from AdamB when we were doing a conversion on a 306, he turned up in his V6 Xantia.