tranny change, now working a "how to" Options

[lake1069]

i brought down my tranny today b/c my clutch was gone, and synchos are mess up. while i was doin it i took some pics, maybe they can help someone down the road. best advice do it with a buddy i spent maybe 6-7 hours on it today and still not finish, with a buddy im sure it would have been less. this weekend will be the interesting thing, the 3rd gear synchro has to be replaced. it was only 29.99 from the dealer but im not gonna pay 400 for someone to put it in. that is all of what i left to do b4 i can put the tranny back on. ill take some more pic while i work on that too.
first i jacked up the car and took the axel off( 45 minutes)


took everything that was in the way off and pulled down the tranny(1.5 hour)


took the old clutch and flywheel off(20 minutes)


had the flywheel turn and put it back on(40 miles and 20 minutes puttin on.)


new clutch set, putting it on ( 1 hour)



This post has been edited by lake1069: Feb 23, 2006 - 12:30 PM

[lake1069]

****still adding changes and pics updated 2/27/06****
howto
once u are 120% sure that you clutch or tranny need to be replaced find the parts that u need, whether its a whole tranny or a clutch. I First thing take a picture or a mental picture of where everything goes especially wire connection, once you got this begin by to remove everything that blocks your view of the transmission. and by this i mean

shifter cable
slave master cylinder
battery
air intake
the black box left of the battery
battery starter

**some other little things, im taking pics of everythings!!!**


use preassure2's advice

another good tip is to take a peice of cardboard, draw a circle on it.
when you remove the bolts that connect the tranny to the block, you can push the bolts thru the cardboard in the corresponding spot on the circle so that you dont forget which bolt came from where. there are a few diffrent sizes and lengths, and they go in from both sides of the tranny.

then something like this



jack up the car, i placed two jack stands on the chassis of the car along with two floor jacks on the engine(will put up pic soon). next thing to do is take out both axels, the right one is pretty easy to take off and left one tends to give trouble because of some safety preasure thing that holds it so in since only the other side has the safety bolts.
ill begin with the right one, take the tire off and remove the axel nut but make sure you remove the safety pin before you do this. This next part is taking off the breaks, **you dont have to do it** but i just do it. to take the brakes off there are two bolts on the back of the rotor i believe they are 17mm. this will release the whole caliper. it is not a good idea to let the caliper hanging from the brake hose since the caliper weighs about 40 pounds so you can use a bungie cord to tie it up or let it rest on something or dont take it off at all.
brake bolts



the two bolts that hold the strut and hub assembly together have to taken off these are 19mm i think.
here is the pic.

struts bolts


after this is done you should be able to pop out the axel from the hub assembly. The axel will not come out right now, there are two bolts that are part of a safety lock to prevent the axel from ever coming out, these are located at the midpoint of the axel, (pic is coming soon) once these have been taken off that axel can be pulled out(pic). for the other side the process is the same. the only difference is that they're is no safety bolt. this can be a pain to get out. here is a old post that can help
http://www.6gc.net/forums/index.php?showtopic=19611&hl=

now that both axels are out, the tranny needs to come down.

SECURING THE ENGINE

the front, back and passenger mounts will need to come off before the tranny comes down. but u cant do this until the engine is secured. im going to tell what i did **not a very safest way**and the hanyes way which is much safer. I raised the car and let it rest on the chassis on two stands(one on each side). i let the engine rest on a floor jack with a piece of wood to provide a surface for it to rest on, than another floor jack with wood right where the tranny meets the engine.



HANYES way

.........*........

This post has been edited by lake1069: Feb 27, 2006 - 12:39 PM