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[Transmission] gearbox removal
#1
hello im a newbie only registered today 
need a step by step guide to removing the gearbox on my berlingo 1.9 04  van
any pics or advice will be gratefully accepted

look online for free haynes manual but to no avail

thrust bearing has packed up so need to replace

basically need help removing driveshafts and draining the box 

help please

thanks phil Smile
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#2
There is a Haynes manual for free download on this very site, have a search and you'll find it.
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#3
tallyboy0hello im a newbie only registered today 
need a step by step guide to removing the gearbox on my berlingo 1.9 04  van
any pics or advice will be gratefully accepted

look online for free haynes manual but to no avail

thrust bearing has packed up so need to replace

basically need help removing driveshafts and draining the box 

help please

thanks phil Smile

Hi Phil,
I've just done the clutch on mine,
There is plenty of room to et the box out ,
But a tricky bit is getting the O/S drive shaft free ..
It sits in an intermediate carrier behind the engine,and has some tricky fixings to fathom out,,

The Haynes manual on here shows some of this, search for it with the search box at the top of the page..

2004 ,1.9d Berlingo Multispace.
called Brian... Smile
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#4
(09-12-2018, 08:50 PM)tallyboy0 Wrote:  hello im a newbie only registered today 
need a step by step guide to removing the gearbox on my berlingo 1.9 04  van
any pics or advice will be gratefully accepted

look online for free haynes manual but to no avail

thrust bearing has packed up so need to replace

basically need help removing driveshafts and draining the box 

help please

thanks phil Smile

Drain gearbox.

I took both driveshafts out, removed air filter housing, battery tray, ECU etc and driver side hub, disc, calliper suspension strut but I left wishbone in place. 

Pop off the gear selector rods and disconnect earth strap any other cables.   

I did mine without a manual (although I've changed gearboxes & clutches in the past)  this one was relatively straight forward.

I replaced the clutch and refitting is just the reverse process. - I cleaned my gearbox before refitting with degreasant/Karcher coz I hate putting dirty bits back on the car.

Gearbox is manageable for one person, I wiggled it out/down from above, then slid out from under the van.  Getting it back in was a quite easy also, again do the reverse but if you can get someone to slide a small trolley jack in underneath the box to support it while you line it up/wiggle it into place - that helps a great deal !

Took me just over 10 hours all in (did service it at same time though) 

I did swear from time to time !
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#5
(11-12-2018, 11:21 AM)Brico Wrote:  
(09-12-2018, 08:50 PM)tallyboy0 Wrote:  hello im a newbie only registered today 
need a step by step guide to removing the gearbox on my berlingo 1.9 04  van
any pics or advice will be gratefully accepted

look online for free haynes manual but to no avail

thrust bearing has packed up so need to replace

basically need help removing driveshafts and draining the box 

help please

thanks phil Smile

Drain gearbox.

I took both driveshafts out, removed air filter housing, battery tray, ECU etc and driver side hub, disc, calliper suspension strut but I left wishbone in place. 

Pop off the gear selector rods and disconnect earth strap any other cables.   

I did mine without a manual (although I've changed gearboxes & clutches in the past)  this one was relatively straight forward.

I replaced the clutch and refitting is just the reverse process. - I cleaned my gearbox before refitting with degreasant/Karcher coz I hate putting dirty bits back on the car.

Gearbox is manageable for one person, I wiggled it out/down from above, then slid out from under the van.  Getting it back in was a quite easy also, again do the reverse but if you can get someone to slide a small trolley jack in underneath the box to support it while you line it up/wiggle it into place - that helps a great deal !

Took me just over 10 hours all in (did service it at same time though) 

I did swear from time to time !



You can save time and aggro by...
Taking pinch bolts out of the bottom ball joints ,
and pulling the whole strut out wards until the shafts come out of the gearbox..
Every thing else on the strut stays where it is..

2004 ,1.9d Berlingo Multispace.
called Brian... Smile
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