lowering my 5 speed gear box

[dazzerT251900td]

I am replacing my seals on my 5 speed gearbox, which is connected to my AAZ engine. Will there be enough flex in the engine mountings to lower my gearbox on two trolley jacks. One under the engine and one under the gear box? I am just wondering how much room I will need with the gear box on top of the trolley jack to get it out from underneath. At the moment my camper is on ramps at the back and was wondering if I need to jack the front up a little bit. I appreciate your help because I haven't done this before. Everything so far has gone well. Ive just got to un bolt the gearbox now from the engine and move my earth strap so its coming off the starter motor instead of the other end of the gear box when I re install it.

Kind regards

Daz

[toomanytoys]

Seals on the output flanges??
Are they leaking badly??

[dazzerT251900td]

Yes both flanges are leaking and gear linkage is leaking too. Is it possible to lower the gearbox on the jack and work on it from there. Because everything else is ok i think. (Clutch etc.) i am fed up of gearbox oil everywhere.

Thanks for your reply

Kind Regards

Darren Clark

[CovKid]

Yes but you get chronic neckache. I did a writeup in the WIKI a long time ago.

[dazzerT251900td]

Thank you covkid.Yes read that write up,great info and i know what you mean.Iam going to drop it and work on it in my garage.
kind regards.Daz

[dazzerT251900td]

Iam struggling at the moment trying to get the boot over the ball and cup on the gear linkage. Looks impossible. Its not an original. Any suggestions anybody?

Thank you

Cheers

Daz

[CovKid]

All you do is remove two nuts/bolts holding plate to flange on gearbox then 13mm nut in centre of gear change bracket - just pulls off complete, drops away.

https://club8090.co.uk/wiki/Ge ... hanism_Pt2" onclick="window.open(this.href);return false;

[colinthefox]

It will make life very much easier lowering (and replacing) your box if you make up a steel plate and bolt it in place of the loose cup on your trolley jack like this.......



Using a couple of wooden wedges you can control the "angle of the dangle". Note the jack is toward the back of the van.

Makes gearboxes a pleasure. Well almost.

[dazzerT251900td]

Hi collinthefox.
Great idea with that steel plate bolted onto the jack.ive built a wooden block,but its not fixed to my jack so iam thinking there will be issues with movement and balancing it correctly.

[busbuddy]

replaced my seals with the box still in the van bolted on the back of a jx motor, didn't lower it at all but you need a proper seal puller not just an old flathead screwdriver

[dazzerT251900td]

Hi there.

Ive got my gear box out of my van yesterday. Bit of a struggle on my own. Didn't have a jack in the right position for balancing but managed to hold the gear box on the jack while lowering it down to a sage position. Now in the stage of cleaning it up and doing the seals. The release bearing is ok and the fork behind is ok and bushes. Going to have to make a different bracket to go onto the jack for when I reinstall it because the wooden one just came off. Ive got to fix it to the jack somehow to keep it balanced while jacking it up into position.

Thanks for your photos and information.

Kind Regards

Darren

[CovKid]

Gearbox is a pig to move on a jack, even when you've found the balancing point. Its even worse when you're trying to line up input shaft. You can struggle for hours sometimes (even with a clutch alignment tool) yet you walk away (frustrated), have a cuppa, come back and it goes straight in!

Its worth making up a sort of welded cradle to fit jack but since you don't often remove the gearbox, we just tend to soldier on.....

[Aidan]

iirc on the wiki there is my design for a wooden platform for the trolley jack, uses an old scrap front upper ball joint to mount the plate to the jack so that it can move in all planes but not fall off, a couple of bits of bent threaded bar allows the box to be attached to the wooden board and you have total control of angles with the security that it can't fall off the jack, essential for safe one man operation

cost one scrap balljoint and nut, something to make a big washer, 18"x6" plywood offcut or bit of victorian skirting board 3 foot of m6 threaded bar and a couple of nuts and washers

[dazzerT251900td]

Cheers Aidan i will look at that and try something like that.Got all my seals from Brickwerks and now after work working on the gearbox.Ive just done the first flange seal,a pig to get old one out.Did not drill and self tap out,i bent a small bar by heating it up and put a little flat hook at the end so it would just sit behind the old seal,the other end of the bar i bent a right angle into it.Then tapped it out with a hammer,moving around the seal.I got my new one in with my hub nut socket against it with block of wood over the end.
Thanks for your help

[dazzerT251900td]

Hi there people.

A quick question; is it better for me to refill my gearbox with oil while I've got it out? Then I can check for leaks before putting it back or would it be too heavy.

Thanks again

Daz