Gearbox removal questions:

[rockthebus]

Hi All
Well the crank seal has now gone, so its gearbox out time.
I've replaced clutches in the past, but have a few questions.

What would the minimum height be to clear the gearbox to come out underneath (working alone, and wanting the minimun hight to lower the box)?
Can anyone recommend ratchet straps which they have used which allow enough turns to lower in one go?
Same for a spigot shaft bearing puller?

Just ordered crank and gearbox seals, spigot bearing, flywheel O ring and felt ring, plus complete clutch from BW, and intend to start on Saturday

Any alternative ideas, on removing it when working solo?

All advice welcomed

Cheers

[Mocki]

I use a trolley Jack with a home made cradle on it , the Jack I have just has enough lift to lower the box down when the van is on my elderly car ramps and axle stands .... I don't have pictures to hand, but basically the cradle arms fit in the ribs on the gear box and hold it tight enough to move it around

[rockthebus]

I use a trolley Jack with a home made cradle on it , the Jack I have just has enough lift to lower the box down when the van is on my elderly car ramps and axle stands .... I don't have pictures to hand, but basically the cradle arms fit in the ribs on the gear box and hold it tight enough to move it around

And does it keep the box at a defined constant angle so as not to put pressure on the input shaft?

If you get the time before saturday a pic would be brilliant, unless you fancy coming to Chesterfield to do mine (for a fee of course!)

[Mocki]

i can take apicture of the jack and cradle, and even the ramps, but i unfortunately havent got the spare time to help you at this short notice .sorry!

you will need another jack to support the engine while the box is being removed to allow the angle to get the box past the crossmember and while it is out

[itchyfeet]

Not saying it's the best way but this is how I did it
https://club8090.co.uk/forum/viewtopic.php?f=37&t=140047" onclick="window.open(this.href);return false;

[Mocki]

Pictures as promised


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[rockthebus]

Pictures as promised


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That looks great. You ought to make and sell some!

I was rather cheeky asking you to come over. It was a bit tongue in cheek so no apology needed!


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[rockthebus]

Not saying it's the best way but this is how I did it
https://club8090.co.uk/forum/viewtopic.php?f=37&t=140047" onclick="window.open(this.href);return false;

I really enjoyed reading your brilliant post last night which is why I posted my question of which straps to buy. Can you recommend any? This will probably the way I go.

I have an engine hoist. Would that be better to hold the engine or am I better of with the 2 ratchet straps?

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[itchyfeet]

I have an engine hoist. Would that be better to hold the engine or am I better of with the 2 ratchet straps?

Thanks
just used any old cheap ratchet strap, don-t think about if too much just do it

I thought of a cradle but once it's down you still have to get the box out so the van has to be so higher, also a 40kg box is unstable if the cradle and jack are not spot on.

Can't see how an engine hoist helps ( you say to hold the engine? wooden blocks do that) but next time I might see how this strap winch could be used to lower and raise the gearbox by routing the strap through the support above the gearbox

https://club8090.co.uk/forum/viewtopic.p ... 0#p8146907" onclick="window.open(this.href);return false;

[rockthebus]

I have an engine hoist. Would that be better to hold the engine or am I better of with the 2 ratchet straps?

Thanks
just used any old cheap ratchet strap, don-t think about if too much just do it

I thought of a cradle but once it's down you still have to get the box out so the van has to be so higher, also a 40kg box is unstable if the cradle and jack are not spot on.

Can't see how an engine hoist helps ( you say to hold the engine? wooden blocks do that) but next time I might see how this strap winch could be used to lower and raise the gearbox by routing the strap through the support above the gearbox

https://club8090.co.uk/forum/viewtopic.p ... 0#p8146907" onclick="window.open(this.href);return false;

I think I understand your procedure now. The 2 straps are around the box. They are lowered until the box clears the crossmember. Then the engine is supported on the front end and the box wiggled off the back and then are the ratchets able to lower it to the ground? I've never used ratchet straps before. How do they work the other way or am I being thick!

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[itchyfeet]

No ratchet straps don't lower well, you can but it's slow, the temptation is to just let if go, if so do it in steps.

Use wooden blocks under the box and just let it drop a few inches each time, pull it up a bit, remove another block and let if go again.
You could do the first bit with a jack and then just drop it the last 100mm or so in a couple of steps.

[rockthebus]

No ratchet straps don't lower well, you can but it's slow, the temptation is to just let if go, if so do it in steps.

Use wooden blocks under the box and just let it drop a few inches each time, pull it up a bit, remove another block and let if go again.
You could do the first bit with a jack and then just drop it the last 100mm or so in a couple of steps.

That makes perfect sense. Thanks.

Why didn't VW put an inspection hole above the box. It would be so much easier! As it would with an be with a pit, or lift!

[itchyfeet]

You could drill a hole, I did consider it

it is only 40 KG you just need control sliding it off and back on the engine, after that you can lower it as you wish.

[rockthebus]

You could drill a hole, I did consider it

it is only 40 KG you just need control sliding it off and back on the engine, after that you can lower it as you wish.

Last quick question:

Do the wheels have to come off to fit the wooden crossmember?

Thanks for your support. Much appreciated

[itchyfeet]

No wheels can stay on, my van tyres were jacked and sitting on wooden blocks the whole time but due to 'safety complaints' pic was removed, you can use ramps like this.