Mk Ii 2.3 Petrol Gearbox Selector Removal Procedure

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I recently had a problem with my gears getting stuck, so only 1st and 2nd were available. Not the most helpful of situations, particularly when reversing  :blush:

 

Having done a search for stuck gears etc. I found several threads outlining similar problems, with possibles causes, and fixes. None I found were very specific about the procedure to remove the selector mechanism.

 

My problem was quite easily resolved by a good clean, and judicious  application of chain grease. Most of the problems I  experienced with regard to removal were mainly to do with not having the correct tools to hand, thereby meaning a trip to the (not so) local tool outlet.

 

I hope I'm not stepping on any toes, but, hoping it will help others, I list below the procedure I used.

 

Raise car approx 150mm and secure on stands or similar.

Remove undertray if fitted. (1 10mm a/f nut centre rear. 4 10mm a/f bolts, 2 per side)

 

Remove battery cover

Remove battery (2 10mm a/f nut to leads. 1 13mm a/f bolt to clamp)

Disconnect 2 plugs to rear of tray. (1 pull apart, 1 (large) secured with 10mm a/f bolt).

Remove large electrical socket from bracket at rear of tray by sliding to the left

Remove bracket from rear of tray. (1 10mm a/f bolt)

Remove 2 10mm a/f bolt from front of expansion tank

Remove 2 10mm a/f bolt from rear of battery tray / tank shroud, and 1 10mm a/f bolt from front lower left of tank shroud.

Lift tank lower hose from bracket at rear of battery tray.

Remove tank shroud.

Remove (by sliding to the left) positive battery cable housing from left of battery tray.

Remove battery tray (4 13mm a/f bolt)

Support gearbox with a jack.

Remove gearbox mount connecting fittings (2 18mm a/f bolts 1 18mm a/f nut)

Remove upper gearbox mount (2 16mm a/f bolts 1 13mmm a/f bolt)

Remove Lower gearbox mount (4 m14 Spline bolts)

Using flat bladed screwdriver or similar, gently prise gear selector cables from ball joints.

Remove 2 spring clips holding reversing light switch to selector mechanism.

Remove reversing light switch.

Remove 6 10mm a/f bolts from selector mechanism

Lower gearbox by approx 50mm.

Ensure selector mechanism is in neutral position.

Gently lift mechanism vertically, until clear of gearbox.

 

Reassembly is essentially a reversal of the above procedure.

 

Make sure to use thread lock compound on gearbox mounting bolts when replacing.

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Oops.

I forgot to mention to remove the expansion tank at the appropriate time