my attempt at replacing a gearbox

[gti mad man]

well there was nothing for it i needed another box so after Aidan had built me a new one it was time to get the old box out ive never doen this before so didnt have a clue........

This is a collection of random bits i thought maybe useful to people doing similar.....



C.v bolts
Noticed how badly mullered i had to make the original to get it out make sure inside the heads are scrapped out the hex ones are super shallow like 4mm!
TOP TIP IF YOU DO ROUND IT OFF TRY A 8MM DOUBLE HEX SOCKET BASHED IN SOLID
Also go buy 12 bolts with washers from vw for about £1.20 they don't round off like the soft ones that come with cv boot kits boots when you torque them up!






Gearbox Drain & Fill plug location
This may seem sill but its not obvious straight away or to a novice where its located
TOP TIP USE WIRE BRUSH ON THE THREAD AND USE PLUS GAS THEN USE A 17MM HEX ON A BAR TO CRACK IT GENTLY WORK IT OUT WITH A BOWL UNDERNEATH






Overall

[Louey]

good stuff - just one thing, always check you can undo the filler nut before you drain any oil out of the drain plug

[rikisha9]

hi gti mad man

any thing needs unbolting, slackening off, un screwing on a motor i
get a spray difuser for gardening filled with diesel an spray all up early on

those drive shaft bolts an other stuff with recessed heads,
spray up with diesel and dig kak out with old paint brush an diesel

i always prefer those hex allen key types bolts, good for torque and
less to mash up, be patient get the job clean, get the tool in tight.

good to see ur pics and good on yer

best

rik

[conrad]

Never tried the diesel approach for un-seizing but I recently replaced and engine in my Saab 9000 and found this stuff to work a real treat

http://www.halfords.com/webapp/wcs/stor ... yId_165594

I'd nearly rounded a nut trying to get it off and no amount of penetrating oil was helping despite me treating it several times a day for 3 days. A big squoosh of shock & unlock and it's was free within seconds!! This stuff really is the business. Hasn't let me down yet. And for those that don't like to shop at Halfords there's a version from Comma but the name escapes me....

E D I T: It's called Frost Bite .