5 Speed Fitment

[Twinky]

Hi guys,

 

I got home early today and thought I might be able to knock over a gearbox replacement.

But ofcourse I was wrong and am up to the part of pulling the box out and disconnecting the clutch cable.

My first question is, how the hell does the cable disconnect from the gearbox bellhousing? Pelase don't tell me that i have to disconnect it from the

pedal and feed it back through. Who ever did the design for the clutch should be shot.... repeatedly.

Second question, How do you guys go about replacing the gearbox? I was told it can be done with the motor still on it's mounts but am finding it quite difficult.

Maybe it's because I am doing it by myself or maybe because I am a noob.

 

My process so far:

 

Disconnect shifter

Drain oil

Disconnect tailshaft (biggest pain in the arse)

Disconnect spedo, reverse sensor

Undo bolts (reletavely painfull)

Undo clutch cable to find that it is stuck through a f###ing gearbox hole, it is at this point that I have finished for today.

[Bamboo]

Pop off the clutch cable circlip

 

unbolt the cross member

 

wriggle it out.

 

It's hard to say you haven't missed something without seeing it.

[Evan G]

on the very front of the clutch cable. theres a clip where it holds on to the clutch fork. you have to remove that! have a good look at it and you should be able to work it out.

 

once this is off you can pull the clutch cable out. its a tight fit. use a little lube and try to pull it out.

 

 

remove the box is easy! don't undo engine mount, make sure all the bolts are off (even that small 12/10mm on the bottom)

 

get the jack under it and yank it out!

[Twinky]

I have taken it off the clutch fork but it is still stuck in the hole of the gearbox, does the very end of the cable disconnect??

The cable does wriggle around but there is no way for it to come loose of the gearbox bellhousing. I'll try giving a bit more of a yank tomorrow

and see if that assembly at the end of the cable comes off.

 

Cheers guys

[Evan G]

give us a pic. there should be just a cylinder on the end of the clutch cable. yank it thru

[morgzz]

its a piece of piss dude.. i use a trolly jack under the gear box to take the weight of it when i pull it out...

 

with the clutch cable you have to pull it through the gearbox side.. 1 cur clip on the cable hole and then reach your hand up to the clutch pedal from the inside and pull the cable off the pedal and then your done

[SLO-030]

Evan, Not all the ends on the clutch cable are the sort where you can pop the end off.

 

Remove the circlip on the firewall and disconnect the cable from the top of the clutch pedal.

 

Then feed it back thru the hole towards the diff.

 

Edit: Pretty much what the post above me says :bash:

Edited November 6, 2010 by SLO-030

[Twinky]

What a shitty design really..... Anyhows I will be doing it all tomorrow as I have run out of time to do anything today.

I was thinking that I would have to end up threading it from the pedal.

[towe001]

And to think, your having trouble with the clutch cable.

Just you wait till it comes to putting the g'box back on. You'll be bald as a shaven badger and the "F" word will be your new best f-ing friend.

 

Yeah sure, its not that hard but its still a bitch and a half if you don't have the room under the car, you finely get the input shaft lined up and things start going walk about.

 

 

 

Have fun and think of me sitting back in my nice comfy chair having a nice cold brewski :)

[SLO-030]

If the old gearbox is taken straight out, the 5speed should slide right on in.

 

Unless your changing the clutch aswell.

[jono1986]

The little clip on the end of the cable comes off dude, that's the problem. You've done the little spring clip but you have to remove the metal part that hooks over the clutch fork. It's not a force job it just pops off.

[SLO-030]

Not all of them have that style of end of them Jono.

[jono1986]

Ah ok, was no vehicle identification so I just went off the 3k 4spd one.

[SLO-030]

Ah yea. Funny, i've only ever encountered this certain type on KE30/55 5spds...

[Twinky]

Farkin finally the thing is in and runs great. I had to take the clutch cable off from the pedal and thread it back through the bellhousing.

Oh the car is a KE55 4K. Putting the box back in was actually easier than getting the f###er out because I compensated for the problems encountered

while taking it out. The tailshaft was officially the hardest part to take out because there is no room for a socket head. Anyhows It is in and I am loving it.

Oh and the box is a KE70 5 speed.

 

Here is all the room I had

 

I used the trolley jack to manouver the box around, made life 100x easier.

 

Now I just have to make up a plate to go over the hole from the 4 speed because the 5 speed shifter sits 90mm further back.

Edited November 7, 2010 by Twinky