DIY Gearbox/Clutch Change *Update* Pics and Problems

[vishpish]

Gonna be honest and say imn pretty sick of searching everywhere for a write up on this for an mr2.all im finding is "how much to do this etc!" i do intend to read the toyota haynes thing on the net tonight but god its so confusing

my car is currently in so many bits im not reallly too concerned at getting my broken box out, but would love somebody to shed some light.

are we talking lifting the engine out disconnecting oil/fuel/coolant or is it tilting the engine in some way or can you just undo the gearbox mount and drop it separately.and what happens to the driveshafts do both have to come out or just the passanger side one out and the drivers side disconnected :S

hope somebody could shed some light on this...confusing the hell outta me!

[ddmotorsport]

when i did mine i tilted the engine to pull the box off. you will have to support the engine with something as well though as it will be held with only one engine mount as you need to undo the other three that are connected to the gearbox (as far as i remember). not too bad a job to be honest, you just need patience i had my box out changed the clutch replaced crank seal and gearbox seals within a day and a half. Thats me and a friend with moderate mechanics knowledge

hope this helps....

any other questions pm me

[vishpish]

hey thanks for the reply mate i vaguely remember hearing of a jacking the engine up tactic at getting the box....do you have to pull out the drriveshafts from the box disconnect all the bolts holding the box onto the engine and mounts then yeah?

cheers

[ddmotorsport]

from what i remember i dropped off the back hubs with the driveshafts attached undone the airbox etc from the top and the clutch slave cylinder... maybe a few other bits and pieces such as gear selector cables too... it will all come to light when you get under there

bit at a time and you will get there

[vishpish]

brilliant man thanks for the help...gonna have a look underneath there tonight/tomoro afternoon ill take some pics if i can to see whats going on....i think im gonna be in for another wd40 soaking right down of the bolts

[paul_4xxxx]

when i did mine, i started off by striping down the passenger side suspesion, remove strut, hub, drive shaft and wishbone...

then undo the gear selector cables and clutch slave, then move to the top.. you will need to strip the airbox and everything out of the way,

support the engine with a trolley jack and remove passenger side mount, front torque mount and rear torque mount,

then undo all bolts around the bell housing, you will also have a sensor on top of the gearbox which needs to be dissconected.

then its just a matter of lowering the engine slightly and pulling the gearbox out..

watch out tho... its very heavy!

i must recomend you find yourself a large prybar for taking the drive shafts off... otherwise you will be there for hours trying to get it off...

also... get a clutch centering tool, otherwise you could damage the new clutch you are fitting, and it may be off-centre wen you put it all back together,,

[Mr2GtBlue]

By the way you dont need to remove hardly any suspension, when i did mine i just left the hubs and struts on and undone one of the hub to strut bolts which allowed me to tilt the hub to allow the driveshafts to pop out of the gearbox, i then just tied the driveshafts out the way with a bit of string, much easier then trying to unbolt the drieshaft s from the hub.

http://mr2.com/TEXT/91T_ClutchChange.html

[paul_4xxxx]

i know you dont have to pull the hubs out, but its much easyer to do that wen you got your car up on axle stands... theres only 4 bolts to undo... i would rather do a half hour extra work than have to xxxx about working around something like a drive shaft.... and where would you tie it up so its out of the way???

[vishpish]

guys thanks for the responses heres what i did and all those promised pics lol

first, on saturday, started taking all the suspension parts off the passanger side incl draining box fluid. first the thin ish suspension bar that angles towards the backbox:



then took off the two big 19mm bolts holding in the damper and then luckily managed to get enough arm strength on the ratchet to get the back 19mm connecting what looked like a control arm that was held in just in front of the driveshaft. this let me pull the hub free.



i then, on instruction from my mate who has worked in a garage(and drives his second mummys corsa) to pull the driveshaft out. so i did and what i ended up doin is getting the rubber bit with loads of grease and being left with the metal bit still in the gearbox which must be a mistake....so i carrier bagged both ends and left it:




then set about the air box and pipes, which was easy enough and then disconnected the bolt and the cable on the top of the starter

now - problems.

1)looking down and leaning over from the passangers side looking into the engine bay (ie rear window to the left, rear boot to the right) where are the bolts located??

2)can i just leave the metal part of the driveshaft in and get the box out or should i as written above get a crowbar and pry it out

3)i have successfully found like 2 bolts holding the box to the block am i blind or where abouts are they!!

[paul_4xxxx]

you should get the inner cv joint out mate... its gonna be a xxx to put back together otherwise...

cant remmember where the bolts are to be honest. on mine i had to remove the throttle and a cooland hose out of the way to get to them.. there should be a hard pipe running accross the top of the gearbox which is held on with 2 bolts going into the gearbox...

have you removed the cluch slave??? i will have a look in a bit to see how many bolt holes there are and i will take a pic for you...