Changing a clutch

[Johntom]

Hi
I am intending to change the clutch on my 2004 1.9 diesel (engine dw8, gearbox Be4r) and had a few questions.
Do I just need to remove the n/s drive shaft and will the gearbox move far enough without removing the crossmember ( or does the gearbox need to drop down out of the way) ?
Roughly how heavy is the gearbox and how do I disconnect the linkages (ball joints)
?
How many hours does the job take on average?
Any other help/info. greatly received.
Many thanks

[mr woo]

Hi
I am intending to change the clutch on my 2004 1.9 diesel (engine dw8, gearbox Be4r) and had a few questions.
Do I just need to remove the n/s drive shaft and will the gearbox move far enough without removing the crossmember ( or does the gearbox need to drop down out of the way) ?
Roughly how heavy is the gearbox and how do I disconnect the linkages (ball joints)
?
How many hours does the job take on average?
Any other help/info. greatly received.
Many thanks

oil out, driveshafts out, pop linkages off, everything else off box, wiggle wiggle wiggle gearbox out onto chest and move to side
no need to take crossmember off
ya can do it in about 3-4 hours fairly easy

[andy-womble]

Hello Mr Woo and welcome, is that Newcastle on Tyne or Newcastle under Lyme???

[mr woo]

Hello Mr Woo and welcome, is that Newcastle on Tyne or Newcastle under Lyme???

upon tyne

[Johntom]

Hi
Thanks for the reply I will give it a go next weekend. Do the drive shafts just pull out of the gearbox and what do I need to undo at the wheel side to release them?
Many thanks

[mr woo]

Hi
Thanks for the reply I will give it a go next weekend. Do the drive shafts just pull out of the gearbox and what do I need to undo at the wheel side to release them?
Many thanks

yes drive shafts just pull out, but drop the oil out first or you will get covered
i popped the strut off the ball joint at bottom and took track rod end off.

too refil the box, on the side of the box looking thru o/s wheelarch their is a plate on box with bolts holding it on, one of those bolts is a 19mm ( i think its a 19 ? ) thats the refil plug

[Johntom]

Help I'm stuck!
I have got the gearbox split from the engine but can't get the o/s longer drive shaft out? I think that all that's keeping the gearbox in place, the I/s drive shaft is fastened where i goes through the engine mount. How do I move the o/s drive shaft out of the box?

[mr woo]

Help I'm stuck!
I have got the gearbox split from the engine but can't get the o/s longer drive shaft out? I think that all that's keeping the gearbox in place, the I/s drive shaft is fastened where i goes through the engine mount. How do I move the o/s drive shaft out of the box?

have you removed the 2 x 10mm nuts from the bolts that go thru the shaft carrier on shaft ? you may have to knock it out of the carrier part

[Johntom]

Many thanks for your reply, I finally got it apart. I hadn't spotted the gearbox mount hiding under the battery tray! with this removed the box moved off the o/s drive shaft. It's pretty much back together now, but i called it a day due to the low temperature.
I couldn't find the refill plug for the gearbox though, could you redescribe it's location.
Once again thanks for the help.

[mr woo]

Many thanks for your reply, I finally got it apart. I hadn't spotted the gearbox mount hiding under the battery tray! with this removed the box moved off the o/s drive shaft. It's pretty much back together now, but i called it a day due to the low temperature.
I couldn't find the refill plug for the gearbox though, could you redescribe it's location.
Once again thanks for the help.

good stuff:thumbsup:

[Image: 198879_1780578146625_1004576529_31992538_7773541_n.jpg]

a pic is much easier than trying to describe it