Club 80-90 Forums

It's a five speed. will check plug today. It's going into gear and driving ok but I'm not happy with it. There's just something not right. Will let you know.

this one and the one beneath are the filler plug. I haven't cleaned any it coz it was clean



and these are of the empty plug



Is it me or should the oil have a metalic sheen to it. It was also foamy whilst emptying.

this is the oil. It looks like its got a metalic paint in it. Trillions of bits.




A little hint for anyone removing the filler plug.....take the gear shift off first. It's so much easier to access the plug. Opened first crank

have i missed something. BUMP

drain plug should have 1 inch long magnet not just stump yours has, metal in the oil that won't stick to magnet is alloy, ie case, something inside the box is rubbing against some part of the case, usually top gear fixed gear on the pinion shaft usually in conjunction with worn pinion bearing and damaged 1st gear and or failed bearing(s)
BUT as 1st and reverse share selector could also be a linkage issue with selecting that plane of movement (or a synchro issue as shared synchro)

So it's definately coming off then? Probably do it myself if you could guide me through. The van will be on the ground, with the back end raised a bit. SO if we could take it from there. Links,vids, and any other help would be great. I'll try and video it also for those in future.

mm

docklad wrote:The van will be on the ground, with the back end raised a bit. SO if we could take it from there. Links,vids, and any other help would be great.

Right. Raise the back on to 4 inch blocks.

My number one tip..........
get a cheap trolley jack and make a plate to bolt to the top of the cup through the hole in the middle. Mine was a bit of scrap metal, but could be thick plywood I suppose. Plus a couple of wooden wedges to stop the gearbox rolling off and control the angle of the dangle. (Yes MM that's your old DH box)


Number two tip. Buy splined bolts to replace the allen headed CV joint bolts. And you'll obviously need a set of splined drivers to put them back. Although you probably won't be able to get a torque wrench in there properly to do them up, work out what 33lb ft feels like on the bench, then do them up that tight under the car.

Nothing wrong with the box is there i made a crab like claw that sits between the ribs with a 1" boss for the trolley jack , it sits at the correct angle to slide straight onto the engine one handed, its up for loan but silly heavy to post
mm

No damage anywhere that I can see. The magnetic stud is a bit of a worry though. If it's not where it should be where is it?
Now for some really thicko questions

Where do I start? What is the the first step apart from telling me not to do it. At the end of the day, I'm able and willing to have a go. If all else fails whats the worst that can happen. All that wil happen is .....I will kill myself. Then you can all blame yourselves.
I've got some spanners and some brain and some time. Over to the best members of the best forum that exists.
Oh by the way I have no intention of messing with the inside of this box. I just want to get it off so the main man can deal with it.

metalmick8y wrote:Nothing wrong with the box is there?

You asking me MM? You mean the one in the pic? No nowt wrong with it, as far as I know, and I wasn't having a go......honest........would I? By virtue of a change of plan it is strictly a spare in case I screwed up the refurb of my No1. Fortunately it's still just a spare, and available for demos.

But seriously, the install with the jack thingy was the best ever. Straight in, no aching arms, and no gearbox on my face.

docklad wrote:Where do I start? What is the the first step apart from telling me not to do it. At the end of the day, I'm able and willing to have a go. If all else fails whats the worst that can happen. All that wil happen is .....I will kill myself. Then you can all blame yourselves.
I've got some spanners and some brain and some time. Over to the best members of the best forum that exists.
Oh by the way I have no intention of messing with the inside of this box. I just want to get it off so the main man can deal with it.

I can't help you get it off (you'll need your best friend for that), and yes, as with most things under the van the worst you can do is kill yourself.

You will need some spanners, and allen keys. You've got to take off all the things that connect to the gearbox. CV joints, then cover with plastic bags and tie the shafts up out of the way with string. Gear linkage, then tie the linkage up out of the way with string. Clutch master cylinder, brackets etc, then tie up out of the way with string. Take off connectors to reverse switch. Disconnect battery. Disconnect starter. Remove starter. Put the jack under, take the weight then take off front mount from chassis, then gearbox. Support the engine from tipping (support the back end of a diesel with a small jack) unbolt from engine, lower gearbox a bit and roll forwards till clear and lower.

And whatever I say, you've got to make sure you're safe. Don't think you can support the weight on your arms. Really.

Thanks very much. You've made it sound much more doo-able. I know it's not brain surgery but every little helps. Mrs Docky is reading and won't allow for mistakes(who's going to lay the carpet and assemble the boys treble wardrobe and adult bunk beds, after decorating their room, should anything happen to me?).

As a side line- I'm 45 this year and have started feeling the strain of getting under and then up from under the van. Might someone offer to indentify which tools will be required for each stage explained above. Ergo, they'll be by my side or in a tray next to me. Massive thanks for help so far. Oh and i'm always checking wiki(not vat fick am i?)

Had a little poke inside gearbox with magnetic torchy thing. You know the ones that extend like a radio ariel with a little LED on the end. Anyway these are the pics of the broken bits I retrieved. No doubts there's more inside. Any idea anyone. Obviously it's some bearing or other and it's fooked.

Oh dear.

You'll be taking the box out then?

nah fill it with ep90
mm
best a an add in wanted for a sh box me thinks