Gearbox Removal

[viking]

Has anyone had any experience using a Sealey engine support beam to aid removal of the gearbox on a Mk1 1.9TDI ?

If so, is it recommended and were any difficulties encountered. I might have to change the clutch at some stage so not sure if an engine hoist would be the better option.

[Neils TDi again]

A four post lift is the easy answer but i have completed a clutch change using a Hoist and two trolley jacks but it was hard work.

 

Reaching the mounting bolts for the offside drive shaft bearing housing is extremely difficult from underneath without the hieght of a ramp.

 

Plus the scars on my head have only just healed.

[viking]

A four post lift is the easy answer but i have completed a clutch change using a Hoist and two trolley jacks but it was hard work.

 

Reaching the mounting bolts for the offside drive shaft bearing housing is extremely difficult from underneath without the hieght of a ramp.

 

Plus the scars on my head have only just healed.

 

That doesn't fill me with confidence. Ford use a support beam which rests on the inner lip of the wings but unsure how safe or fit for purpose a propriotory support beam will be, for example one manufactured by sealey tools.

[Neils TDi again]

The Ford version is the same as the Sealey version an dit does rest on the wing mounting area but it has a brace to the top of the suspension mounting and is a very good tool, I chose not to buy it cos I am a cheapskate and thought I could do it without but it would have been soooo much easier if I had one.

 

If your gonna do more than one then it would be worth investing but for just one job ?

[viking]

I'm only going to be doing this job on my own vehicle and looking for a safe cost effective

way of changing the clutch. The engine must be suspended using either an engine hoist or

overhead support beam. The cost of hiring a hoist might be near to the price of buying a

Support beam (usefull to have for future diy maintenance). Just wanted to know if anyone

had used one succesfully before I buy. Seen two weight categories, 300KG and 500KG.

Any advise as to what would be most suitable to support the 1.9 TDI ?

[Staffy]

I know this hasn't got much to do with support beams and stuff but its generally about gearbox removal and i'd appreciatge some help.

Yesterday i was driving my mk1 1.9 td galaxy when all of a suden the gear lever felt very stiff. I had to stop at a junction and then i couldn't select first or second gear so i pulled away in 3rd. At a convenient place i pulled over and found that 3rd and 4th gear could be selected but 1st and 2nd, 5th and reverse could not be selected, the gear stick was very stiff and i was unable to move it from side to side. I managed to get home and i've had a look at the selector cables and they are fine ( i disconnected them both from the selector assembly and the cables work ok). What might be causing the gear stick to be so stiff and prevent me from selecting gears? Although i can get 3rd and 4th the stick is very stiff and i can hear a grinding sound coming from the selector mechanism on top of the gearbox. If the gearbox needs replacing is this a big job and would the engine need to come out? Although i've never removed a gearbox i'm more than willing to have a go because the car is undriveable and i've got other transport i can use. Any help please....

[Neils TDi again]

I know this hasn't got much to do with support beams and stuff but its generally about gearbox removal and i'd appreciatge some help.

Yesterday i was driving my mk1 1.9 td galaxy when all of a suden the gear lever felt very stiff. I had to stop at a junction and then i couldn't select first or second gear so i pulled away in 3rd. At a convenient place i pulled over and found that 3rd and 4th gear could be selected but 1st and 2nd, 5th and reverse could not be selected, the gear stick was very stiff and i was unable to move it from side to side. I managed to get home and i've had a look at the selector cables and they are fine ( i disconnected them both from the selector assembly and the cables work ok). What might be causing the gear stick to be so stiff and prevent me from selecting gears? Although i can get 3rd and 4th the stick is very stiff and i can hear a grinding sound coming from the selector mechanism on top of the gearbox. If the gearbox needs replacing is this a big job and would the engine need to come out? Although i've never removed a gearbox i'm more than willing to have a go because the car is undriveable and i've got other transport i can use. Any help please....

 

 

With someone elses help get them to move the gearstick from left to right while you try and observe the top of the selector where the cables terminate.

 

You should see the cables moving the selector shaft, if my theory is correct and it happened to me then the shaft is moving but the selector inside the gearbox is not and the 7mm Metric Fine threaded bolt which holds the selector arm onto the shaft inside the gearbox has sheared off and is now stuck between the selector and the housing. I am afraid if this is the case then it is a gearbox out and stripped job, if the bolt had sheared and dropped into the sump of the gearbox you may have been able to get away with lifting the selector stack out the top of the box and replacing the bolt but not if its jammed into the selector.

Edited March 11, 2007 by neil_wiles

[MadBaz]

I'm only going to be doing this job on my own vehicle and looking for a safe cost effective

way of changing the clutch. The engine must be suspended using either an engine hoist or

overhead support beam. The cost of hiring a hoist might be near to the price of buying a

Support beam (usefull to have for future diy maintenance). Just wanted to know if anyone

had used one succesfully before I buy. Seen two weight categories, 300KG and 500KG.

Any advise as to what would be most suitable to support the 1.9 TDI ?

 

Safest and easiest way is to give it to someone else to do.

 

I did my clutch last year and it was an absolute pig, I used a hoist and trolley jack and had great problems lining engine and box up, with the beam this shold be much easier in theory.

 

Setup a swear box and put in a quid every time you curse and when you've finished you'll have enough to take it to a dealer to do next time.

[romseygalaxy]

I'm only going to be doing this job on my own vehicle and looking for a safe cost effective

way of changing the clutch. The engine must be suspended using either an engine hoist or

overhead support beam. The cost of hiring a hoist might be near to the price of buying a

Support beam (usefull to have for future diy maintenance). Just wanted to know if anyone

had used one succesfully before I buy. Seen two weight categories, 300KG and 500KG.

Any advise as to what would be most suitable to support the 1.9 TDI ?

 

Safest and easiest way is to give it to someone else to do.

 

I did my clutch last year and it was an absolute pig, I used a hoist and trolley jack and had great problems lining engine and box up, with the beam this shold be much easier in theory.

 

Setup a swear box and put in a quid every time you curse and when you've finished you'll have enough to take it to a dealer to do next time.

[tim-spam]

The Ford version is the same as the Sealey version and it does rest on the wing mounting area but it has a brace to the top of the suspension mounting and is a very good tool

The ones I looked at just seemed to rest in the wing mounting channels - the problem I would see is that the wing channels on a Galaxy have a considerable slope. Wouldn't this tend to make the feet slip, and how would the adjustment screw work so far away from the vertical?

 

If this tool can be made to work effectively on a Galaxy, it would probably represent a very good investment for those who do all of their own repair and maintenance. I've seen them available for around

[viking]

The Ford version is the same as the Sealey version and it does rest on the wing mounting area but it has a brace to the top of the suspension mounting and is a very good tool

The ones I looked at just seemed to rest in the wing mounting channels - the problem I would see is that the wing channels on a Galaxy have a considerable slope. Wouldn't this tend to make the feet slip, and how would the adjustment screw work so far away from the vertical?

 

If this tool can be made to work effectively on a Galaxy, it would probably represent a very good investment for those who do all of their own repair and maintenance. I've seen them available for around

[tim-spam]

Looking at a diagram of the sealey support beam it appears that the vertical line is achieved by the pivots either end. As far as the steep angle of the wings are concerned I would have thought that a thin strip of steel in the form of an 'L' shape bolted to the inner wing (one on each side) in front of the feet would stop any slipping. Ford remove 2 of the inner wing bolts for this purpose.

If there are indeed pivots at each end, then it should work well - can anyone actually confirm if this is the case? The thin strips of steel are a good idea, and probably safer than just relying on the rubber inserts resting against a bolt head.

 

Thanks.