Gearbox rebuild

[Jonathan]

Now I have it out (very easy job !) had a chance to look at it a bit.

Haven't got a 36mm socket yet to take the 2ndry shaft end nut off so I haven't split the casing however the 5th gear looks fine and the diff looks OK too - remaining undrained oil was a little dirty and had a tiny trace of metalic in it but nothing too bad tbh.

Anyone who's done this recomend a list of parts to replace, whilst I got it out I might as well give it a good once over. Seals, gaskets etc go without saying also bearings which have excess play I can replace as well.

Anything else to look for apart from the obvious signs of wear on the movign parts ?

On the daft side there was only 1 bolt holding each mounding arm on to the gearbox mounts !!! (should be 3 each side). Good job I caught this, a good thrash could have jerked the engine/gearbox enough to crack on of the mounting arm legs which would have been pretty messy

[M Blur]

Gotta try Kev over at GTO Engineering Jonathan.

[Vulcan Grey]

Now I have it out (very easy job !) had a chance to look at it a bit.

Haven't got a 36mm socket yet to take the 2ndry shaft end nut off so I haven't split the casing however the 5th gear looks fine and the diff looks OK too - remaining undrained oil was a little dirty and had a tiny trace of metalic in it but nothing too bad tbh.

Anyone who's done this recomend a list of parts to replace, whilst I got it out I might as well give it a good once over. Seals, gaskets etc go without saying also bearings which have excess play I can replace as well.

Anything else to look for apart from the obvious signs of wear on the movign parts ?

On the daft side there was only 1 bolt holding each mounding arm on to the gearbox mounts !!! (should be 3 each side). Good job I caught this, a good thrash could have jerked the engine/gearbox enough to crack on of the mounting arm legs which would have been pretty messy

You can split the case, no need to take apart the shafts to look inside. Just undo the 3 bolts in the plate that is around 5th gear.

[Jonathan]

Ah right, I was only taking the back end nuts off incase the shaft / gears had to be stripped off.

I would bet getting that 36mm nut off the back is a right pain without it being in the box or damaging the teeth holding it in a vice.

Did you replace much on yours ?

[esprithk]

Oh...I am doing this right now..

here are my part list from SJ sportscars UK

SYNCRO RING for 3rd, 4th, & 5th

SYNCRO RING for 1st & 2nd

gaskets/sealings and bearings if there is any.

and I install these upgraded parts from PUK Esprit Racing

(1) +35% Torque Clutch

(2) ATB LSD

(3) "you may also consider" the 5th gear kit **ratio 0.75:1

NOTE: someone has posted a diagram about how to unscrew all the nuts and bows..(and direction of which screws/nuts to go first)

Edited September 11, 2006 by esprithk

[Vulcan Grey]

Ah right, I was only taking the back end nuts off incase the shaft / gears had to be stripped off.

I would bet getting that 36mm nut off the back is a right pain without it being in the box or damaging the teeth holding it in a vice.

Did you replace much on yours ?

My gearbox is fine, I was just looking at it's health and resealing the case, and replacing all the o-rings.

[Jonathan]

Quick question to those who might have done this job.

I noticed the manual has a few errors in it as far as bolt positions and lengths (well, my UN1 is definatly slightly different), thats not a prob but the torque settings say m12 bolts to be done at 90nm.....what M12 bolts !?

afaik all the bolts in there are m8, m10 and m10 fine (large case half bolts x4). The bell housing is m10 and the rear cover are m8. Bell housing to engine and support legs are all M10 as well....am I missing something here ?