Removing Gearbox

[gazza82]

How easy? Clutch release bearing has gone so need to get this done .. decision is DIY or pay my local garage ...

Looked at the repair guide and it seems to get complicated around the bit with cranes and engine hoists ..

Thanks!

[Capncol]

Gazza, I did one last week. You can do it with a pair of trolley jacks, one under engine, one under gearbox. Get yourself a release bearing guide sleeve as well as you will probably find half the release bearing *welded* to it.
If you get a Valeo clutch, it comes with a disposable plastic clutch aligning tool.
About 2.5 - 3hrs

Good time to replace gearbox oil too.

[gazza82]

Thanks Col ... time for some bedtime reading .. one Haynes manual ...

[Capncol]

Basically take everything out above the gearbox, battery, battery tray, airfilter and airway pipes.
Drain gearbox oil, seperate n/s bottom balljoint. Optionally remove o/s driveshaft support but I leave it in place.
Remove 3 starter fixing bolts. Remove bolts from bell housing. Remove slave cylinder or cable depending on clutch operation. Remove gear change rods.
Using 2 trolley jacks-
Place 1 under engine, 1 under gearbox and remove gearbox mounts. Lower engine and gearbox enough to slide gearbox into space between inner wing and subframe It won't come out completely, but you only need to creat enough space to remove the clutch assembly. Achieve this by juggling the jacks up and down and the gearbox will rotate forward enough to give you the space to remove the clutch. When refitting the new clutch, cut down the handle on the plastic alignment tool to make it easier to use. Then put it all back together.