Club 80-90 Forums

Ok I have done a search on tech and found one thread but it does not really help me, converted my 1982 Aircooled to water cooled and done it the correct way, it has now got a 1987 complete wiring loom in Complete dash and instruments replaced from an 1987 diesel donor fitted a Diesel 1.6 TD Engine code SB. Removed my DK 4 speed box and refitted a 4 speed diesel box, Having problems with diesel box cannot engage any gears and secondly the rear mounting bracket to cross member is not long enough. 2 bolt holes short,
Decide to put my Aircooled box back in but I am having difficulty in removing the mainshaft , Belhousing is removed Bently Man, page 35.5 says remove circlip and slide spacer up the shaft then unscrew shaft. My prob ' is the said spacer has a gear wheel (think it says reverse gear) on it and after sliding it up the shaft turning it to unscrew the differental is still turning I cannot slide it all the way off as it hits the diff crown wheel,
Any help would be greatly appreciated,

Try holding/locking the shaft at the back of the sliding sleeve and simply undo the front section of the shaft.

The sleeve and the circlip are only there to stop the whole thing from seperating.

Regards

Fritz,,,,,,,,

As shown below, well the shafts anyway,,,,

[IMG:640:480]http://i13.photobucket.com/albums/a292/ ... box001.jpg[/img]

Jeff, speak to Aidan ..... no insult Fritz old chap

Ian.

Thanks for quick reply Fritzz and Ian
I understand what you mean Fritz but the piccy you put up is the other end of the box not the bell end, (no pun intended) I can just about get a set of mole grips down, thats how i pulled the sleave up but as i said there is a gear wheel attached to the sleave, I will try and lock it up the next attempt will be thursday nite,
Fritz I will give you a bell tomoro nite

just a thought but wont a petrol box on a diesel make your bus phenominally slow? it's early and i'm probs being a bit thick but they rev much lower don't they?

Depends on what engine he's using.. if a TDi etc, then he needs the "tall" gearing, if a non turbo 1/17/19... gonna struggle..

As said speak with AIdan, he will advise what to do... and he aint far from you either..

Fritz, I reckon that crown wheel and pinion are fooooobarred
Geoff sorry I couldn't talk on staurday, a bit off road and needed both hands on the wheel.
Catch me Friday am if you still need to know.
A

my old gearbox.eh fritz.....

Fritz, I reckon that crown wheel and pinion are fooooobarred

BTW the differential gets in the way of splitting the input shaft, there are a couple of positions where it is easier to get it out, but still a pain, easier on a diff lock syncro than a 2wd diff too. I undo the adjusting rings, move the diff aside and give myself room to work, but I have the tool for the rings. Plenty of people get out a die grinder and clearance the diff housing appropriately. what happens to the swarf I hate to think.
One of those where Bentley doesn't help much

isnt this a machine from outer space??[img:640:480]http://i13.photobucket.com/albums/a292/ ... box001.jpg[/img]

I have a DK gearbox fitted to my 1.6td.I did the gearbox change my self and no it can be a bit of a fiddle removing the input shaft out of the dk box. You will see the reverse gear is in a diffrent position to your diesel gearbox.It will come out but you need turn the diff untill you find a position for a tight clearance position for removal.Its a case of of keep trying.I dont have any problems with to high gearing and use it for towing.Others on hear may disagree but i am talking from experiance .

OK thanks everyone for help and advice, it is now sorted as Camper say,s it was tight very little clearance but can be done with a little perseverance
I found you lay the box down on a bench rotate the housing on the crown untill you find a flat spot, that way there is abit more side to side movement in the shaft, I was trying to unscrew it whilst the box was standing on its end. Job done