'96 VR6 - Auto to Manual [Build]

[MilkIsYum]

Had to have a break, but I've kept busy ordering parts (how could I resist) and doing small things.

I've been rewrapping all the loom behind the dash, it was covered in degrading tape and deteriorating foam.

New parts coming in:

- Water pipe kit, I figured if I'm going this far I may as well do as much preventative maintenance.
- Shifter Mounting Bracket Bushing Kit
- Water Pump
- Cabin Filter
- Torque Wrench (Once I'm reassembling I'll need to be able to tighten everything back to the right measurements!)

[MilkIsYum]

I've been trying to get some good hours in, but I can't seem to separate the automatic transmission from the engine. I've removed every bolt that I can see, and it still won't separate.

Going to have a read around vortex etc. and try and see what I'm missing.

I removed the CV joints from the transmission, but the axles won't come out of the hub. I've tried some penetrative spray and a rubber mallet, but neither would move.

Does anyone have the VW tool or something similar for removing axles?

[MilkIsYum]

Pulled out the auto transmission! The thing is huge, and insanely tight to manoeuvre in the engine bay.



I missed the torque converter bolts when removing the transmission, which left even less space to move things around. I ended up rotating the whole transmission by 90* degrees clockwise using and engine crane + jacks/jack stands, which allowed it to slide straight off! Definitely the easiest way to drop the transmission, especially if you're doing it solo.

Torque Converter still attached to the engine:
(picture taken from left wheel well)



And here is the car resting in the garage:

[MilkIsYum]

Today I painted the interior pillars from grey to black. They are all relatively easy to get off. I scrubbed them all with warm soapy water beforehand to remove anything on the surface and then towel dried them off as well as let them stand outside for a while.



I took a piece of some stock black interior paneling and compared it to a few different paints in Autobarn, I ended up going with the one above. (Motortech Matt Black)

The painting took a while, since I was doing light coats and quite a few pieces. The good news is though, the colour is indistinguishable from the factory black! I'll upload some photos in a few days when I can get some snaps in the sun.

I'm going to give them a while to cure, and then I'll give the paint a bit of a scratch and rub to see how well they will hold up.

[MilkIsYum]

Just received some mail to tie me over during the week!

Got these JOM blue coilovers for a steal off eBay. Brand New, shipped from Germany for $399.

[HaydEn]

Good luck.

Depending on how you run them. I suggest you get the rear springs reset a few inches lower. They are too soft when lowish

[MilkIsYum]

I'm content with them not being slammed. I'll keep it in mind when putting them in, thanks!

[MilkIsYum]

My impact gun stripped one of these bolts and the rest are pretty soft too. (not my picture, mine's a drive plate, not a fly wheel).

Pretty frustrated, not looking forward to trying to get these out. Not sure how I'll do it. Heat it up a bit, use a chisel to try and bite into the bolt and chip it loose?

Ugh.

[HaydEn]

Ouch. ...

Vice grips

[cliftronix]

Grind the head off, once there is no pressure on the threads it will thread out easy. The are insanely tight so I doubt anything would get them loose while still under pressure.

[MilkIsYum]

Grind the head off, once there is no pressure on the threads it will thread out easy. The are insanely tight so I doubt anything would get them loose while still under pressure.

I'm worried I'm going to grind the heads off and be left with seized headless bolts in there though :-/ I guess I'll have to test my luck.

I think I'll try a few alternatives and then I can always resort to grinding the heads!

[KKK VR6]

U should NEVER use power/impact tools on mechanical and chassis parts!
Wd40 + using a extension over the wrench will always work, hard work though but that's life.
If the heads have to be cut off, and they get stuck, u can use a screw extractor to get them out.

[MilkIsYum]

U should NEVER use power/impact tools on mechanical and chassis parts!

Lesson learnt. Is it for the reason above, people like me shearing the bolts?

[KKK VR6]

Lol, they tend to cause cross threading, and rounding of the heads.
And depending on the part, they can damage it.

[MilkIsYum]

So, I decided to try and grind the bolt heads off...

The tools:



After half an hour (changing discs, etc):



After I ground down the metal I was able to get the drive plate off!

Gif of me pulling the plate off:

Imgur

The remaining bolts were quite firm, but using some vice grips I was able to start taking them out:



Thanks for the input on helping me remove these!