Engine out (again!)

[Dangerous Dave]

Today was the day I picked to change my gearbox over, as the output to the angle gear on my old gearbox was knackered (see pic).

I managed to get a gearbox from Braydons Volvo in London. But it was from a '98 AWD and had the concentric slave cylinder. No problem I thoug, just swap the bits over as its bound to have the same mounting holes...... wrong! In the end I had to seperate both gearboxes and swap the bellhousings around.

I can't believe how crappy my old box was inside.

Car resting on axle stands
http://i150.photobucket.com/albums/s101/bomb192uk/15092009174.jpg

Old gearbox housing (filthy)
http://i150.photobucket.com/albums/s101/bomb192uk/15092009175.jpg

New gearbox housing (as it came, just with oil drained, lovely and clean)
http://i150.photobucket.com/albums/s101/bomb192uk/15092009176.jpg

Old bellhousing cleaned up with internals from new gearbox
http://i150.photobucket.com/albums/s101/bomb192uk/15092009177.jpg

Buggered angle gear output on old box
http://i150.photobucket.com/albums/s101/bomb192uk/15092009181.jpg

Diff from old box (note the splined output for the angle gear at the top)
http://i150.photobucket.com/albums/s101/bomb192uk/15092009186.jpg

Mess on my parents driveway hehehe
http://i150.photobucket.com/albums/s101/bomb192uk/15092009191.jpg

Engine
http://i150.photobucket.com/albums/s101/bomb192uk/15092009193.jpg

Shiny new connecting sleeve
http://i150.photobucket.com/albums/s101/bomb192uk/15092009195.jpg


Engine is now back in the car with just a few bits left to put on tomorrow. And then its done (until I need a new clutch LOL)

[badger1980]

thumps up to u u work quicker than i have ever seen

[Alan M]

He likes doing the clutch on a regular basis though lol. Thats why he can do the work reasonably fast.

[Dangerous Dave]

Forgot to mention I also did the rear crank seal, and cleaned all the crap from behind the flywheel too

[flyingbrick]

Top bloke I know were to come for mine (if and when) lol..............

[Dangerous Dave]

What a day!

Started off this morning at 10.30 by trying to get the downpipe back in, but ended up having to drop the rear of the subframe by 6 inches to get it past the angle gear.

Then had to clean and re-grease the cv joints on the propshaft and fit it back on the car, but couldn't find where I'd put the bolts (found them in the end).

Then lots of little fiddly jobs which took ages to do (like the bloody ac pump bolts, and fitting the drivebelt). Finally finished tonight at 9pm, engine running (first time no issues) no bits left over. Only problem I've got now is that the gearshift has moved across 1 place, so 1st is where 3rd would be, and 5th is closer to my leg. I think the cable bracket on the gearbox is in a different position to the old one, so will swap them over tomorrow night.

Happy now I've got my AWD back (YEAH)

[dooby]

Nice one, taking apart gearboxes is on my list of things to mess about with.

Not a lot holding the engine to the subframe with no geabox attached, is there :-)

Cheers, Pete

[Dangerous Dave]

LOL, no there isn't. Because of the angle gear there isn't a rear engine mounting, just a mounting on the end of the gearbox, so all thats holding the engine is the front mount and the mount at the timing belt end (and the trolley jack LOL)

Was fun to take apart the gearbox and see whats inside. I was quite disappointed really, I expected something on a more grander scale (considering how bloody heavy it was!). And I now have a spare one to play around with.

[Justin]

Nice work bomb :)