syncro gearbox removal

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garyd
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syncro gearbox removal

Post by garyd »

I shall be having my gearbox overhauled by Aidan shortly and so I have been researching on here for any tips regarding taking the box out. The following notes come from the 'clutch removal' thread on the Wiki, the VW workshop manual and my memory of what's under there. Maybe those who have experience of removing syncro gearboxes could comment with regard to any further tips, anything I've missed or things not to do. Looking forward to you comments thanks.

Syncro Gearbox Removal (TD or GTi engines)

Jack up your van high enough to gain comfortable access to the box. Put axle stands or wheel ramps (at least 2 tonners) in place before you attempt to get underneath, and rattle the van to make sure they are secure, then chock the front wheels.
Remove the engine access hatch & disconnect the battery.
Begin by removing the propshaft and its protection rails. Also the engine undertray. Drain the gearbox oil & take a picture of the magnetic drain plug. Refit drain plug. Remove the drive shaft bolts, (clean out the Allen or spline headed holes before attempting to loosen them, make sure the tool is a very good fit). (These are HT cap socket headed bolts, and should have small hard dimpled washers under them, and 3-curved spreader plates.) Bag the CVs and tie the loose drive shafts up out of the way.
Remove the gearchange shaft mounting bracket from the gearbox casing flange. Remove clutch hydraulic line bracket from gearbox. Unbolt slave cylinder from bracket & tie-up. (Remove the cap from the fluid reservoir-under the dash pod-and fit a plastic bag or similar, hold the plastic in place by screwing the cap down tight. This will minimise fluid loss should the piston drop from the cylinder.)
Remove cables from reverse light switch & diff lock warning light switch. Unbolt diff-lock vacuum unit, carefully knock out roll pin and tie up unit. Disconnect gearbox breather banjo fitting.
Disconnect cables from starter motor. Undo top engine/gearbox bolts and remove starter motor. Attach a support to the back (pulley end) of the engine to hold/pull it up. (Without the gearbox it will tip towards the back of the vehicle.) This support must have capacity to lift the engine end higher than its rest position - see below.
Place the trolley jack under the g/box using suitable packing pieces, and remove the bolts and earth strap from the front mounting.
With the weight still on the jack remove the other bolts that fasten the g/box onto the engine. Carefully lower the jack down VERY slowly, checking that nothing in the engine bay is getting stretched or squashed. Drop the front flange about 150mm (6"). Tension your engine support in this position. Ease the gearbox off the engine towards the front of the van and, once clear of the clutch, lower the jack fully, ease the box onto a board on the floor and drag it from underneath the van.
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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garyd
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Re: syncro gearbox removal

Post by garyd »

Since no-one has offered any comments I have to assume that I have got it right?
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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silverbullet
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Re: syncro gearbox removal

Post by silverbullet »

Reads ok to me Gary. A length of 4" sqare timbet across the hatch and a ratchet strap is a winner for supporting the flywheel end of the engine, whatever its type.
The transmission will want to balance about an inconvenient point, so a timber knock-up to fill the step behind the diff housing will help find the sweet spot. Use an ARNO or similar strap to tie the transmission to your trolley jack.
Dont forget the white sheet on the floor to catch the difflock pin!
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

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Jim San
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Re: syncro gearbox removal

Post by Jim San »

I have the pleasure of this task in the near future - i'll keep this and use it for reference, cheers Gary.
:ok
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max and caddy
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Re: syncro gearbox removal

Post by max and caddy »

Removal is easy...putting it back is the hard bit...I just used the wife..

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silverbullet
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Re: syncro gearbox removal

Post by silverbullet »

Most people smoke after :lol:
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

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Aidan
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Re: syncro gearbox removal

Post by Aidan »

inline 4 engine lift the back of the engine to get the nose of the gearbox to come down and clear the chassis member don't pull on the box to get it to pass the chassis, a ratchet strap and a length of wood across the engine bay works

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garyd
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Re: syncro gearbox removal

Post by garyd »

Thanks for those comments, guys.

Does anyone have a picture to illustrate the balance point or the wood block Ian describes?
Garyd

1990 Transporter syncro camper
2 litre AGG 'GTi' engine

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silverbullet
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Re: syncro gearbox removal

Post by silverbullet »

IIRC the balance point is *near* the blind circular boss on the bottom of the casing. I made up a sort-of-adjustable steel cradle with a peg that located in that boss, and a pair of square rails that slotted into the machined notches that run along the lower fins on the diff housing.

About to go home, I'll take a pic shortly.
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

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silverbullet
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Re: syncro gearbox removal

Post by silverbullet »

Image
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

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silverbullet
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Re: syncro gearbox removal

Post by silverbullet »

Made from 25mm square ERW btw
85 syncro Caravelle twin slider Oettinger T3200E-6
90 SA Microbus supercharged wbx/UN1 project

http://www.025motorsport.com

max and caddy
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Re: syncro gearbox removal

Post by max and caddy »

That's an engineered solution...rather just grunt it in myself...

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ninja.turtle007
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Re: syncro gearbox removal

Post by ninja.turtle007 »

Mines on the jack still after I pulled it out last night. I'll take a pic tomorrow and post it up.
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irishkeet
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Re: syncro gearbox removal

Post by irishkeet »

a good read on my to do list :mrgreen:

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