Clutch Tutorial-How to Remove Gear Box and Clutch

[GT-TD04]

Right, first off this is a brief description of the steps needed.



1) Jack the car up at suitable points.

2)Empty gearbox oil.

3)Unbolt lower arm from hub.

4)Pull driveshafts out from gearbox.

5)Unclip the gear selectors.

6)Unbolt clutch slave cylinder line from gearbox.

7)Unbolt clutch slave cylinder (2 x 12mm bolts).

8)Remove 5 main gearbox - engine bolts (17mm) and all smaller ones holding debris cover onto side of gearbox.

9)Remove starter motor (i do this to make removal and re-fitting of gearbox easier).

10)Remove front passanger side gearbox mount from chassis (2 x bolts) & rear gearbox mount from chassis (5 x bolts).

11)Place a jack under the gearbox, slide box sidewards away from engine and rest it on the jack as you lower it to the ground.

12)Lock flywheel up against the ground and unbolt the clutch from the flywheel.

13)Use an alignment tool to line up the new clutch disc with the cover, and bolt complete setup to the flywheel, then remove alignment tool.



Photos



Remove gear selectors.
http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00876.jpg



Unbolt clutch line and remove sensor

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00877.jpg


Unbolt and tuck aside the slave cylinder (this way you wont have to bleed the clutch)

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00878.jpg


Drain gear box oil

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00879.jpg


IMPORTANT--Place stands or jack under gearbox--
IMPORTANT


Remove 2 x front passanger side gear box mount bolts.

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00880.jpg


Remove rear gear box mount (either take complete mount from chassis or pop the rubber mount out,i remove complete thing for ease of access)

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00882.jpg


Unbolt lower arm from hub on both sides.

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00886.jpg

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00893.jpg


Undo the inner CV boot clip on both sides (the clip nearest the gearbox)
http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00895.jpg


And pull the drive shafts out of the gear box (Cover CV joints with bags to stop dirt,moisture getting in and damaging them)

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00897.jpg


Unbolt the starter motor & disconnect earthing line and sensor.Pull out of gearbox(i do this just to give me a bit more room when re-fitting gearbox)
http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00892.jpg


Remove all gearbox bolts ( 5 x main ones and a few smaller ones)

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00888.jpg
http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00890.jpg

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00891.jpg


Once youre sure the clutch line, all cables and wiring, and all the bolts are removed, jiggle the gearbox off sideways.Pulling the shaft out of the clutch.<br />

Abracadabra, alakazam! One gear box.

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00902.jpg

Back to the clutch, jam the flywheel up from moving with a bar and remove all the clutch cover bolts

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00903.jpg


Use an alignment tool to centralise the new clutch disc with the cover, and clamp them together.All tools are different depending on the brand so i didnt take a photo.


You want the clutch disc perfectly central, otherwise you'll never get the gearbox back on.

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00907.jpg



Look inside the gearbox and remove the old bearing from the shaft by pulling on the 2 pins, it should release the bearing.

Apply bearing grease to the shaft and slide the new bearing on, lock it in place with the clip.WIPE OF EXCESS GREASE!

http://i2.photobucket.com/albums/y26/saxoragger/clutch/DSC00908.jpg


Now re-fitting is just a reversal, get 2 people to lift the gearbox or use an engine hoist/normal jack underneath the gearbox to get it back up into position.

It may take a while to get the shaft back into position, sometimes they go in first time and sometimes they can take all day but bear with it.<br />

Also dont forget to re-fill the gearbox with the correct oil, depending on if you have LSD fitted or not.


Now go make a cuppa and admire the gripping power of a new clutch


Craig.






This is compliments of (Craig)Glanza_Ragger & UKSC

Just to add there is a few small bolts at the bottom of the gearbox holding the metal cover in place,two 12's and two 10's i think.

Could this be moved to the Tutorial section aswell please

Dan

[glanza_dan]

very usefull i have to change my gearbox sometime.

[GT-TD04]

very usefull i have to change my gearbox sometime.
Be prepared to get pissed off, it can take a good few hours,you can be looking for a bolt for 30mins lol:haha:

Oh and can this be moved to tutorial??

[lingl9z]

if im just replacing the gbox without changing clutch do i have to allinge anything etc?

cheers rich

[GT-TD04]

if im just replacing the gbox without changing clutch do i have to allinge anything etc?

cheers rich
Just the gear box as long as it is the same (no extra lsd etc)
If its just the box the clutch doesnt have to be touched,just align the dowels back up when putting the gear box on STRAIGHT, or you could bust the thrust bearing

Dan

[Jay]

Cheers Dan, I've copied the thread to the Awesome Section earlier.

If Glanza Ragger would like a little rep let me know. :cool:

[lingl9z]

Just the gear box as long as it is the same (no extra lsd etc)
If its just the box the clutch doesnt have to be touched,just align the dowels back up when putting the gear box on STRAIGHT, or you could bust the thrust bearing

Dan

Sweet cheers buddy, isit a job a 'novice' should attempt?

[GT-TD04]

Sweet cheers buddy, isit a job a 'novice' should attempt?

LOL no, but i never touched a gear box before and i took out 2 gear boxs and replaced one clutch in 2 days,but that was without the tutorial.

You'll need two people and a few jacks and axle stands

Dan

Sound Jay, dunno if he's even here, just when i was looking for one i couldnt find one and i found this after...c##t:haha:

[lingl9z]

Cheers buddy appreciate that mate! i may give it ago =]

[I_<3_Boost]

This isnt me being silly, but if your only doing the clutch you shouldnt have to touch the gbox oil......

[GT-TD04]

This isnt me being silly, but if your only doing the clutch you shouldnt have to touch the gbox oil......

How do you figure that??:confused::confused::confused:

[Luke.R]

True you don't have to drain the gearbox if you leave the inner cv joints in because the oil can't get out anyway.

Although it wont harm it doing a oil change on it I spose.

[GT-TD04]

True you don't have to drain the gearbox if you leave the inner cv joints in because the oil can't get out anyway.

Although it wont harm it doing a oil change on it I spose.
Not sure how that works ,but i wouldnt be what you'd call a gearbox tech head

[Luke.R]

Well technically it's not the inner cv joints I mean the cups that the cv joints fit into, but aslong as that part is left in the box on both sides then the oil won't leak out.

But then as I say for the sake of a 24mm drain plug you may aswell change it cos you never know how long it's been in there, but on the last starlet clutch I did, the bloke didn't wanna pay for new oil, so it stayed in there lol.

[GT-TD04]

Well technically it's not the inner cv joints I mean the cups that the cv joints fit into, but aslong as that part is left in the box on both sides then the oil won't leak out.

But then as I say for the sake of a 24mm drain plug you may aswell change it cos you never know how long it's been in there, but on the last starlet clutch I did, the bloke didn't wanna pay for new oil, so it stayed in there lol.

Scrooge lol, either that or you stabbed him pretty good for the work lol

I think id always change mine for the minds sake