jtek 0 Posted April 5, 2007 i have read the guide to gearbox changing and the haynes manual, and today we got the new clutch on the car. I most note here that we have not taken the radiator or any other panels off of the car, we merely have the bonnet up lol. the car is up in jacks but in retrospect, they are not spectacularly high. we have got the box back into position and the splined shaft appears to be just into the hole on the clutch, but we really are stuck at this point. it is incredibly frustrating as the gearbox mount onto the chassis restricts movement and we were unable to remove its stud, and generally its just a bastard of a job. does anybody have any tips on easier way to the box over the splined shaft and into position? thanks Share this post Link to post Share on other sites
jonnie205 1 Posted April 5, 2007 hav you lined up the centre plate in the clucth? the box wont go on if its not lined up. The spike can get in the way but you can unscrew it from the box Share this post Link to post Share on other sites
Banjo 1 Posted April 5, 2007 As jonnie's said make sure the clutch is centered and also its prob easier to take the engine mount/battery tray out. Ben Share this post Link to post Share on other sites
jtek 0 Posted April 5, 2007 yeah i used self fabricated line up tool and got it pretty central, but at the moment as we look into the housing there is staill about 15-20mm of spline left which is what confuses me as to why it wont go back, ah well tomorrow is another day lol Share this post Link to post Share on other sites
steve@cornwall 100 Posted April 5, 2007 yeah i used self fabricated line up tool and got it pretty central, but at the moment as we look into the housing there is staill about 15-20mm of spline left which is what confuses me as to why it wont go back, ah well tomorrow is another day lol Have you removed the bottom and top engine mounts? this can give the extra lean to the engine for the gearbox mount "spike" to clear the chassis leg. Obviously support engine with trolley jack to control the drop. I don't remove the battery tray as the 13mm bolts underneath can be a real pain.I just remove the actual rubber/metal mount. Share this post Link to post Share on other sites
jtek 0 Posted April 5, 2007 yeah i may just do that actually, i think our main problem is crap access to get hold of the box and shove it into position, and that bloody spike lol, if its lower down then we may be able to get a clean push on it. cheers Share this post Link to post Share on other sites
inferno 1 Posted April 5, 2007 i always jack the car as high as i can, and almost sit up under it with the box on my chest to get it in. take the 4 13mm bolts holding the battery tray on out, use a 6inch extention to put the bottom ones back in with first gearbox is always the hardest, dont beat yourself up about it! is the input shaft actually in the clutch? if the splines dont line up push the box on the clutch and have a mate turn the crank pulley a little to line them all up. Share this post Link to post Share on other sites
steve@cornwall 100 Posted April 5, 2007 i always jack the car as high as i can, and almost sit up under it with the box on my chest to get it in. take the 4 13mm bolts holding the battery tray on out, use a 6inch extention to put the bottom ones back in with first gearbox is always the hardest, dont beat yourself up about it! is the input shaft actually in the clutch? if the splines dont line up push the box on the clutch and have a mate turn the crank pulley a little to line them all up. I rest the 'box on my legs whilst sitting under it then lift into position by bending knees Share this post Link to post Share on other sites
inferno 1 Posted April 5, 2007 I rest the 'box on my legs whilst sitting under it then lift into position by bending knees i have longer legs and stronger ab's than u Share this post Link to post Share on other sites
steve@cornwall 100 Posted April 5, 2007 i have longer legs and stronger ab's than u So does an average schoolgirl Share this post Link to post Share on other sites
mickie 3 Posted April 5, 2007 i lowered the engine quite a bit but i guess its a bit dodgy doing it that way.. mainly becuase of the stud on gearbox Share this post Link to post Share on other sites
pugman211 0 Posted April 6, 2007 like the others say, make sure the input shaft is lined up!! i had the same trouble with my impreza gearbox, and what was stopping that, was the input shaft was NOT lined upto the spigot bearing that sits in the flywheel! If all else fails, lots of wiggling usually works for me followed by some persuasive words!!!! lol Share this post Link to post Share on other sites
jtek 0 Posted April 6, 2007 cheers for the advice everyone, we checked everything you all said and i got under the box and it more or less went straight in, just putting the rest of the car back together now lol Share this post Link to post Share on other sites
