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Thread: Few questions around gearbox removal

  1. #1
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default Few questions around gearbox removal

    Hey folks,

    Just getting ready to swap my flywheel (CDTI 150)but have a few questions I need answering before I start.

    1 - Do I need to disconnect the steering column from the rack and does the PS fluid bottle come off with the subframe or should I leave it in place. (Vec b just removed the bolt from inside the car on the column and let me drop the rack)

    2 - Gearbox locking.... Do I need to know about any method of locking the box in gear before removal. (Just changed corsa box and needed a pin in the inside of the car by the lever to hold it in gear. Was also a button on the linkage to lock it in.) hoping the vec has something similar.

    cheers

  2. #2
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    PS just read something about a speed spring that can be damaged if I drop the subframe completely from the car. Any ideas on what this is ?

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    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Must be someone on here who has done this before ????

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    Admin & Merchandise Manager bigmac's Avatar
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    Vehicle : insignia

    Trim : irmscher

    Engine : 2.0 cdti

    Year : 2009

    Default

    Maybe post in correct section

    Now moved

    Irmscher Insignia CDTI 130

    MOD'S...Irmscher front spoiler, Irmscher mats, Irmscher door pins, Irmscher rear spoiler, Irmscher grille, Irmscher skirt & exhausts,Irmscher Roof spoiler MOD'S TO COME..Side skirts,Wheels

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    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Quote Originally Posted by bigmac View Post
    Maybe post in correct section

    Now moved
    Thought it was lol. I want to talk about a Vectra. I dont need to trouble shoot one as know whats wrong with it lol

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    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Bump

  7. #7
    Regular Member Ste's Avatar
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    Default

    I recently changed the gearbox on my 1.8

    I didn't fully remove the sub frame, didn't remove the steering rack or the fluid bottle.

    I did disconnect the steering column pinch bolt from the rack.

    I did have the benefit of a pit, and a helper.

    The gearbox wasn't too difficult to remove, but is heavy and awkward. I managed to 'spring' the subframe enough to make a gap big enough to remove, after removing all the mounting bolts and resting it on wooden blocks.


    The buttons etc on the Corsa gearbox and gear shift are for setting the linkages in the correct position. There is no need to lock the gearbox or anything else, and the selection method is cable - these just 'pop' off and only fit in one position.

    The only thing that made things difficult was the plastic bracket which made final separation of gearbox from engine a bit of drag.

    An engine support bar is useful (when you disconnect the mounts you don't want to the engine to drop) I made one using a short plank placed front to rear from the bonnet slam panel to the skuttle panel and had 2 long 'J' bolt hooking the engine lifting eyes. This allowed up and down adjustment to get the gearbox off and out. I do have overhead lifting tackle on a RSJ spanning the garage, but that meant taking the bonnet off and the car becomes un-moveable, and I didn't want that.

  8. #8
    Regular Member Gavin2.6's Avatar
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    Vehicle : 1.9 cdti SRI & 2.6 Vec B & Mk1 Fiesta XR2

    Trim : 2 batteries. 2k RMS. 2x 15 SPL's

    Engine : CDTI 200 16V


    Default

    Thanks Ste.

    Sounds like your plan is pretty much the same as mine. The pinch bolt talked about, is this the same as the vec b as in inside the footwell. If so does he just undo to allow the whole rack drop with the subframe.

    Did my vec b with just 2 jacks. One on the sump and one to help lift the box back in. Also used the same method of dropping the subby onto blocks..

    Good news about not locking the box. I had a mooch at the linkage last night and looks easy enough to pop off so happy about that.

    So to recap -

    drop bumper and plastics
    drop both ball joints.
    remove drive shafts from hubs (dont want to remove them from box side at all lol)
    remove all passy suspension
    undo steering pinch bolt
    drop sub frame enough for box to slide out.
    remove starter.
    remove plastic bits on top of box
    remove box.

    Any other tips would be great. Got all the bits now. just need motivation to start it lol....

  9. #9
    Regular Member Ste's Avatar
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    Default

    Remove bumper? I didn't
    I removed drive shafts from gearbox side, drained oil first.
    Pinch bolt is under bonnet, directly onto the rack.
    Can't remember removing starter either, or maybe did undo bolts but just moved to the side????
    Yeah, battery and tray out.

    Wing gearbox support would be a bit fiddly if you don't have the 'right tools'
    Gear selectors just 'pop' off with a bit of prising, and cable unclips from the support bracket.
    The only thing that made things difficult was the plastic bracket which made final separation of gearbox from engine a bit of drag. This is located at about the 2 o'clock position when viewing the engine from the gearbox side. I snapped the plactic tabs off, as they were always in the way and then the gearbox went on easily.
    You also have to disconnect the clutch pipe on the side of the gearbox. So you will have to bleed it afterwards. Might be a good idea to flush out the clutch system.


    One point to note is that the combined clutch / brake fluid reservoir is a little strange. The clutch section is at the rear and doesn't seem to want to fill up very well when you add fluid...... Luckily the bottle is translucent and you can see if it is full.....

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