1.8 GDI change clutch
Hi everyone I'm in the south of France.I saw a post saying it was possible to drop thr gearbox and transfer box.Looked at photos.I spent all day today and only succeeded in raising the car, taking off the drive shafts and the lower three bellhousing bolts,the easy ones.How do you get at the rest and the two for the starter.Help! I suspect you get at them from inside,tomorrows job.Peter
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OMG! OK! will do.Could you pop over to the south of France and bring your special tools .While your here you could pick the grapes the vendange is just started.Thankyou for your brilliant answer.Peter
Gosh, french humour....!
If you have the GDI engine, the fixation might be different. We do not have the GDI engine in Australia.
On the MPI engine the starter motor can be a pain if you never done it. The special tool that Bob advised you to use is, in french just for you ! a "cle a oeillet articule" la taille est 14 pour nos moteur, and yes access is not the best....
We all try to help each other here....
Happy io
I had another go todayI've
I had another go todayI've got 5 of the bellhousing bolts out.Also the slave cylinder,and the interior bits gear lever high low lever and hand brake.I broke more than i'd hoped in getting the plastic covers off.I couldn't figger out the clips inbetween the two argh!Next Im going to lower the whole lot to try and get at the remaining three from the rear, 14mm long extentions and flexible.The GDI must be different as I just can't figure out where the starter is,but it must act on the flywheel?.Peter
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That gear box is very heavy (estimate, I could be wrong 60 to 70 kg) and not easy to put back in as there isn't much room. If you struggle to find the bolt, the rest is not going to get better. I am not trying to turn you away or tell you what you can or cannot but more giving you the friendliest warning I can.
Can you send some pictures of what you see, and have removed, we might be able to guide you with them.
Happy io
Hi,I've got nine bolts out.I
Hi,I've got nine bolts out.I used a very lovely fitting fourteen mm three eighth drive socket with a fine ratchet and fitted it on the bolt and using half inch socket extensions gave it a tap just to start it .It worked.I'm now working on the big drop using two trolley jacks.Peter ps twenty five degrees in the garage every things a bit slippy.I've just got back from my olive grove where I'm building a shed or folly as my wife calls it.Two hours concreting at seven o'clock is enough.Peter
From memory ...
The transfer box, if I remember correctly, has five switches, each with a connector on a pigtail - fairly easy to release - and the last is the vehicle speed sensor, near the tail shaft on the left side - if that's the one that's giving you trouble, look closely at it, you'll see a U shaped wire "bail" - hook it with a small screwdriver or pick and remove it, and then the connector will just pull off.
Replace the bail on the connector (the harness side) immediately to avoid losing it - it does not have to be removed when reconnecting the sensor, just push the connector on to the sensor and it will snap into place.
The wire bail does not actually have to be removed to disconnect the harness plug - the ends of the U snap over two latches, and you can slip them - personally I find it easier to remove & replace.
If you don't see the bail - go take a look at the throttle servo connector - it's a similar setup, but in a much more visible location.
Hi Everyone,I got brave and
Hi Everyone,I got brave and spent an hour this afetrnoon.I got the gearbox back enough to disconnect the pressure plate,worn to the rivets on the pressure plate side ,relief.I've got it all hanging from a strap held in the gearbox hole with a bar across on the inside.I slid the transmission out using a ratchet strap to the back axle and winched it back.I'm now looking at the release bearing and wondering how the two springs work,.I don't really want to drop it right down as it's primed to go back in .I used a centralising kit for the plate, first time using one.Peter
Syndicate
removal of gearbox
read this: http://pajerio.com/forum/diy-how-install-11925-low-range-gears
it covers pulling the gearbox out in the first sections.
* the balance point of the garbox / transfer box is right where the rear mount is - that is the point you want to support it on a trolly jack etc to allow the box to be pulled back.
* you need to remove both shifters, and disconnect the transfer box wiring harnesses
* you need to unbolt the clutch slave from the outside of the gearbox - you can then tuck it up out of the way
* you can undo ALL of the bolts on the gearbox bellhousing using a 14mm socket, a uni and a heap of extension bars. I used about 5 20cm bars to get them all and some I had to pass over the top of the gearbox crossmember to get the angle right
* this is all relativly easy - there is one really hard bolt though on the bellhousing, it's under the starter motor / intake manifold and faces forwards.
I had to buy a special tool ratchet spanner to get it out - and mine was seized so i had to heat up the bellhousing with a hot-air gun to get it to move.
get the io as high as you possibly can - I had mine on stands on wheel rims to get a good 3' under the floor so I could sit cross-legged etc.
...and do your rear main seal while you have the flywheel off - it's an easy 10minute job, well worth it
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