Gearbox removal rear main replacement

Two breather pipes from the gearbox.
One is clipped with a 10mm you can see in the photo and the breather bolt is visible too.

Close up of the breather bolt.

The other breather bolt and pipe can be reached from the top through the hole by the gear selector.
From this photo you can see the breather pipe and bolt.
You can also see the large bolt that had the cable clamp on it which needs to be removed and also the transfer selector clip that holds the transfer cable on to the high / low ratio gearbox selector.

Remove the breather bolts (both of them) and fit blanking plates in the place or put the bolts back in to stop any dirt getting into the gearbox.

With all the cables and plugs undone, pull the cables up through the gear shift lever hole and cable tie them out the way.

When the breather pipes are removed, cable tie them up and out the way.

Forgot the photo

With all that removed and a blanking bolt in the hole, I removed the 4 bolts holding the transfer cable to the gearbox.
There are 4 long bolts you can see in the picture and this holds the metal bracket on to the gearbox and also metal clamp that all the cables clip onto. I removed all of this. Also at the top of the picture there is a small 10 mm bolt that clamps a cable on to the gearbox. This needs to be removed too. With this off, I pulled everything up through the hole by the gear stick and cable tied them up and out the way.

Brewedintheuk said:

With all that removed and a blanking bolt in the hole, I removed the 4 bolts holding the transfer cable to the gearbox.
There are 4 long bolts you can see in the picture and this holds the metal bracket on to the gearbox and also metal clamp that all the cables clip onto. I removed all of this. Also at the top of the picture there is a small 10 mm bolt that clamps a cable on to the gearbox. This needs to be removed too. With this off, I pulled everything up through the hole by the gear stick and cable tied them up and out the way.

Click to expand...

personally id leave all that on and let come out with box

Another view of the clamp, this time removed.

jamesmartin said:

personally id leave all that on and let come out with box

Click to expand...

I thought about it, but wondered if it would get in the way and get damaged. Hanes manual says to remove the cable from the bracket, but looking at it , I thought it would need to be set up again after doing that, so I think that would be a whole load of grief.
In all honestly I figured undoing a few bolts now would save me a lot of grief later.
Plus, I dragged the gearbox out the way as I had a few more bits to do and it would have just go in the way, so it made life easier taking it off.

I'll try and finish this tomorrow. But I'm at work early tomorrow.

you thought right whereas its not rocket science to reset its anther pain to get right ,but ,leaving on doesnt hurt

excellent thread so far

Now was the time to support the gearbox.
I would strongly recommend buying an engine support.
To get the gearbox out I just used my trolley jack to support the weight and a block of wood to protect the housing.
I also used a second trolley jack to stop it from twisting and put an axle stand under the bell housing to protect it from dropping out.
This was fine, until it came to dropping it down the last bit onto the floor.
To put it back in I bought a Sealey ES502 engine support, cost me £71.00 but I don't know how I would have done it otherwise.

Now, with the gearbox supported I removed the two gearbox mounts on the side of the gearbox.
First the large one, undoing the 4 bolts and then the nut at the bottom.

Then the other, smaller support. Again, the 4 bolts and the one nut.

With all the bolts and nuts removed, I jacked the gearbox up enough to get both the supports out and put these to one side.
Then let the gearbox down again to where it was.

Just to give everyone an idea of where the bolts are.
A diagram of the bolts and the position.
They are all the same size apart from the two on the sides, which are longer than the others.
The only one that was a little bit tricky to get to was the one shown on the top right.

From this picture you can see the bolt at the top right, it was hidden under the gearbox sound insulation cover, so was a bit tricky to get to as this cover kept falling back over it.
The photo shows the bolt under the cover, on the top above where the starter motor went.

From this photo you can see the bottom bolts, and the longer bolt at the top of the photo.
They're all pretty easy to get out after this, the other top bolt is very easy to get to from the top of the engine bay.

Brewedintheuk said:

From this picture you can see the bolt at the top right, it was hidden under the gearbox sound insulation cover, so was a bit tricky to get to as this cover kept falling back over it.
The photo shows the bolt under the cover, on the top above where the starter motor went.

Click to expand...

lowering box right down as far as possible makes removing cover easy

With all the bolts out, and the gearbox well supported still, one last check to make sure nothing is going to catch the gearbox.
I cable tied the pipe that runs along the top out of the way and made sure that the clips that the bolts go through were out the way and not going to hinder the gearbox coming out.