Gearbox Replacement

[SpeciP3]

hello guys and girls,

Going to replace the gearbox in the mk1.
Want to know if this can be done without taking out the engine?
What gear will I need to do it and how long should I allow to do it?
Also, if I was to upgrade to a 5 speed, is there anything else that will need to be changed for it to work (i.e. linkages, etc)?

It's been too long with a noisy gearbox, time to get a quiet one

cheers,
Michael

[paulie71]

hello guys and girls,

Going to replace the gearbox in the mk1.
Want to know if this can be done without taking out the engine?
What gear will I need to do it and how long should I allow to do it?
Also, if I was to upgrade to a 5 speed, is there anything else that will need to be changed for it to work (i.e. linkages, etc)?

It's been too long with a noisy gearbox, time to get a quiet one

cheers,
Michael

Yes indeed you can remove the gearbox with engine in-situ. I would have a Haynes Manual handy so you can refer to it and plan your work.

Also make sure you have a clean, clear surface with containers for all the bits you plan to remove.

raise the front of the car with some sturdy car stands so there is at least enough room under the front to remove the box from under the car.

Remove the gear linkages, clutch cable, speedo cable and wiring to the reverse switch, remove the starter motor, flywheel guard (if it's still there) then with your trusty trolley jack or a block and tackle winch supporting the engine only, release the gearbox, front and rear engine mounts,

Disconnect anything that impedes this movement (eg: radiator hoses etc) and lower until you can physically remove the box from under the car. Use another jack to hold the box in place as you undo the bolts that go around the box connecting it to the engine block, slide it out and hey presto gearbox removed.

While you are at it, replace the clutch, and pressure plate, and if time permits have the flywheel machined to create a nice new surface for the friction disc.

You will need a 5 speed linkage kit, and make sure you empty the replacement box of oil before putting it all back together. Some like to fill the box while it is out, but just another leaking liquid and some more weight. Put some good gear oil in the box once all re-assembled.

Have fun!

[gtimk5]

The gearbox mount is totally different.
foc64 can now make them and they look a treat

[SpeciP3]

thanks Paulie, sounds good.
got myself a haynes manual so shall be looking at that

Thanks Andrew i'll pm foc about a mount.

cheers

[foc64]

The gearbox mount is totally different.
foc64 can now make them and they look a treat

Andrew does that mean I'll owe you a spotter's fee???????????

Chris

[gtimk5]

Hey Chris!!!
Get out in the workshop and keep building mate, No time for bludging, will give you my bank details next time
Andrew

[SpeciP3]

haha! you'll have to start advertising.

foc you have pm

[roccodingo]

Undo the CV joints at the transmission flanges too, otherwise its going to be a bugger to remove.

On the 5 speed box, you may need to swap the flanges to match your CV joint size ( 90 or 100 mm ) the haynes may show that proceedure...And as mentioned, your better of getting all the five speed shift parts as there are a few differences.

[paulie71]

Undo the CV joints at the transmission flanges too, otherwise its going to be a bugger to remove.

On the 5 speed box, you may need to swap the flanges to match your CV joint size ( 90 or 100 mm ) the haynes may show that proceedure...And as mentioned, your better of getting all the five speed shift parts as there are a few differences.

oops my bad-they do need to be removed. Good pick-up there roccodingo. When you do it by instinct sometimes the verbalising of the task is a bit hard.

Pity help the people I train!

[oracle1]

I'm doing it right now

I just got out from underneath the MK1, the box is back in and by tommorow afternoon I will be able to give you a wrap up on the whole sorry tale


look here

http://www.vwwatercooled.org.au/newforum/upload/showthread.php?t=34686&page=2

[AUC-05L]

i changed the clutch in mine a while back, took a full weekend and alot of swearing. first time i done it though. .