Hi all,

 

Can anyone give me an idea in how hard it is to fit the clutch and gearbox with the engine already in place? I dont want to be removing the engine again as i heard this is the better way.

 

Is it possible if i get the car high enough in the air?

 

Thanks Dan

No need to remove the engine at all, it's reasonably easy, if you are mechanically minded, the only awkward bit is getting to the top bolts on the bell housing, you'll need a 3 foot ratchet extension, there is walkthroughs in the FAQ section, but after you have removed the exhaust, propshaft etc. it is pretty straight forward, providing you have the front of the car (or all of it is easier) about 18 inches or more off the ground.... Be careful tho, it's pretty heavy if the cars not on a lifter....

if you had deleted your EGR which im sure you have you can get the top 2 bolts from the top makes it alot easier. I got my gearbox on and off with the car just up on normal axle stands there is enough room to get it under

You would be insane to remove engine just to fit clutch and box.

 

Tudor and Gonzo have given good advice. It can be done on your own (with a lot of struggle), but ideally a 2+ person some for slightly less struggle getting the box in.

 

Standard axle stands give enough height. Seal the rear gearbox output with a latex glove or something, or risk getting a face full of fluid as you fight with it.

 

Perfect Clutch alignment is critical for a trouble-free fitment.

Hi all,

 

Can anyone give me an idea in how hard it is to fit the clutch and gearbox with the engine already in place? I dont want to be removing the engine again as i heard this is the better way.

 

Is it possible if i get the car high enough in the air?

 

Thanks Dan

 

I normally use normal axle stands for front and trolley jack under diff, only jack back up to turn prop to undo top bolts on prop, then drop it again,

 

I can do it easy in 3-4hrs laying on my back, tea and fag breaks too.

 

Remove:

 

1,battery terminal,

 

2,exhaust,

 

3,starter motor,

 

4,slave cylinder,

 

5,heat sheild,

 

6,gearbox mount, (use trolley jack hold box up)

 

7,gear linkage,

 

8,drain oil from box,

 

9,undo 2bolts holding prop up (take note of 2 thick washers) mark prop with tip ex pen where you split it in the middle then undo 4bolts, may need small crow bar or strong screwdriver to split prop.

 

10,undo all wiring connectors on box ( should be 3: speed sensor, neutral switch, reverse lights)

 

11,Undo all bolts round the bell housing, (top ones with few extensions to go over the top of box ) one as an earth strap.

 

12,box should be ready to come off I get underneath the box and drop it on my knees and chest, if you dont fancy it use trolley jack.

 

13,undo clutch pressure plate bolts, and your halfway their.

 

Then its reverse order putting it back, i also undo the 4big turbo pipes at front of engine lets the engine drop back a little makes it easier to slide box back on,

had one before where had to jack the front of engine up a little with piece of wood and jack to get more clearence at the top of box,

 

and remember them prop washers and your mark,

 

and new gearbox oil,( i put the prop back in so dont leak out, and refil with oil why box is hanging down a bit before you jack it up and bolt mount on, easier to fill unless you have a pump,

 

Goodluck mate.

Clutch gearbox removal and refit is something that can be done at home but it is one job that is so easy on a 2 post ramp you need to may want to consider getting a garage to do it for you, £200 to £250 as an average cost, drive in drive out all done in around 2.5 hours, see if there are any clutch garages near to you.

 

Jeff TT

Thanks for the info guys!

 

Im putting everything back together from the rebuild that started years ago.

Ive got a few more questions?

 

Will i need to tilt or get the engine in a certain position? Will i need to undo the engine mount nuts?

 

Ive got a 1 piece prop now so will the diff need to be fitted last to allow the prob to fit in place?

A mechanic also said i might have to fit the gearbox with the prob attached because once the gearbox is in place it would be positioned so that the prob wont fit on to the gearbox? Apparently its like that with the 200sx

 

Glad its possible to be fitted with normal axle stands as i was thinking id maybe have to find some lorry axle stands or something. EGR has been removed so thats a good start i guess.

Im going to try it myself and this is going to be a first. Im thinking of laying on the floor with the gearbox on my chest and using my legs and arms to get it in place.

Any other tips would be great!

 

Cheers Dan

Edited September 9, 201114 yr by GIBSTER-TT

no need to undo the engine mount nuts however take the hardpipes off until the gearbox is bolted up if they are on as the engine will lean back anyway.

 

One piece prop fits fine with diff on as i did mine

 

i used 2 trolley jacks on my gearbox to get it on and then its justa case of getting to it the right height and push it forward

If you are really struggling use a jack on a piece of wood on the front crank pulley to get the engine to lean backwards a little more but obviously don't go mad.

Thanks for the info guys!

 

Im putting everything back together from the rebuild that started years ago.

Ive got a few more questions?

 

Will i need to tilt or get the engine in a certain position? Will i need to undo the engine mount nuts?

 

Ive got a 1 piece prop now so will the diff need to be fitted last to allow the prob to fit in place?

A mechanic also said i might have to fit the gearbox with the prob attached because once the gearbox is in place it would be positioned so that the prob wont fit on to the gearbox? Apparently its like that with the 200sx

 

Glad its possible to be fitted with normal axle stands as i was thinking id maybe have to find some lorry axle stands or something. EGR has been removed so thats a good start i guess.

Im going to try it myself and this is going to be a first. Im thinking of laying on the floor with the gearbox on my chest and using my legs and arms to get it in place.

Any other tips would be great!

 

Cheers Dan

 

I lay on my back with head near engine and legs towards back of car, slide gearbox up on my belly and legs, lift with my arms and knees and you can look up and see between engine and box see how its lining up its heavy but not to bad, but make sure you get it slid right on and dont let it hang on the shaft, once you have it half in you cant give up until its in,

 

once you undo gearbox mount engine will fall to roughly the position you want,

 

Where are you in essex pm me if you get stuck mate.

I lay on my back with head near engine and legs towards back of car, slide gearbox up on my belly and legs, lift with my arms and knees and you can look up and see between engine and box see how its lining up its heavy but not to bad, but make sure you get it slid right on and dont let it hang on the shaft, once you have it half in you cant give up until its in,

 

once you undo gearbox mount engine will fall to roughly the position you want,

 

Where are you in essex pm me if you get stuck mate.

 

Thanks for the great info mate. My unit is in rayleigh ill give it a go over the weekend hopefully. I'll let you know if I get stuck.

Thanks for the great info mate. My unit is in rayleigh ill give it a go over the weekend hopefully. I'll let you know if I get stuck.[/quote

 

Thats near leigh on sea, aint it, got bit by an adder their and had to go hospital for anti venom lol. Took the adder to the hospital with me they all thought i was mental.

 

Love reptiles couldnt resist holding it even though i knew it was poisonous,

Was a little faster at biting then a grass snake lol.

 

Yeah let me know if you get stuck love messing with zeds, Anything for a day out, May even be able to go meet me old mate the adder again NOT.

Well your more than welcome to come and give a hand? Im in need of someone thats got more know how than me to finish this build plus i might get my enthusiasm back as well. Ill supply food and water and some petrol money for ya troubles.

 

Your mad lol. What did you do with the snake after? Yea its before lea on sea just off the A127. I make sure its adder free

Edited September 11, 201114 yr by GIBSTER-TT

Well your more than welcome to come and give a hand? Im in need of someone thats got more know how than me to finish this build plus i might get my enthusiasm back as well. Ill supply food and water and some petrol money for ya troubles.

 

Your mad lol. What did you do with the snake after? Yea its before lea on sea just off the A127. I make sure its adder free

 

they Let the adder go in the hospital grounds lol, when i come out the next day the nurses were all sitting on top of the benches with their feet where you would normally sit.

 

When you looking at doing it mate,

 

And were sort something out mate.

Haha i bet they loved you then ;)

 

Whens best for you im sure i cant do pretty much anytime after work or make time during the weekend?

 

Cheers

Haha i bet they loved you then ;)

 

Whens best for you im sure i cant do pretty much anytime after work or make time during the weekend?

 

Cheers

 

Just priced up a job in chelmsford audi tt headgasket, should find out in morning when im doing it,

 

So if you like take head off audi tt send it to be skimmed and come round to you, i live in kent now so chelmsford would be closer to you.

 

Let you know tomorrow what day im doing tt and let me know if its any good for you.

Ok cool sounds good to me :)