Is taking a gearbox off a car/van something for the pros?

alexthecheese

alexthecheese

alexthecheese

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Or something for a mug like me, who thinks he can save himself a few hundred quid by doing the job myself.

I put the deposit down on a new motorhome the other day, with the knowledge that the syncro on 2nd gear is knackered. Unless the revs drop to near-idle, it won't go into gear without vocally giving you grief.

I've found a place in Shrewsbury that will strip down a gearbox and rebuild it for £200 + parts, which seems amazingly cheap. I've been quoted £700 for the same, but that includes getting the gearbox in and out and letting me drive it away.

Is taking a gearbox out hugely difficult? It's on a Citroen Relay van from 1999.

This might be the most pointless thread in the world, but if someone says "mmm, it's not too bad" then I might recruit some help from some mechanic mates and give it a go.
 
If you have a haynes manual, a suitable jack(s), something suitable to rest and wheel the gearbox about on and a few strong mates it would be do-able imo.

They are a very heavy mofo though, and depending on the design of the van could and probably will require other bits and pieces to come out before hand, such as drive/prop shafts etc. Certainly for me the hardest part would be supporting the gearbox as it is detached from the van, and then re-attaching it when done.

It will be a good excuse to also change the clutch as well as any recommended parts for that van while the gearbox is off though.

In short, yes, but get 2 mates to help, one of who should be experienced with cars and can direct you and the other guy :)
 
Jack it up, put it on axle stands and have a look to see what's involved. I'd certainly have a go myself and I have no mechanical training. I've done my own cars myself though.

Make sure you change the clutch, etc whilst it is out. Saves a lot of time/money in the future.
 
lawz said:
If you have a haynes manual, a suitable jack(s), something suitable to rest and wheel the gearbox about on and a few strong mates it would be do-able imo.

They are a very heavy mofo though, and depending on the design of the van could and probably will require other bits and pieces to come out before hand, such as drive/prop shafts etc. Certainly for me the hardest part would be supporting the gearbox as it is detached from the van, and then re-attaching it when done.

It will be a good excuse to also change the clutch as well as any recommended parts for that van while the gearbox is off though.

In short, yes, but get 2 mates to help, one of who should be experienced with cars and can direct you and the other guy :)
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Man up, slide it off and bench press it downwards! A jack can be used for this though. Putting a gearbox back in lying underneath it on your own is NOT fun.
 
Done a few driveway gearbox swaps using nothing more than two trolley jacks, two axle stands, chocks, and a Halfords pro socket set.
 
I've changed the clutch and gearbox in a relay van on the drive and it's fairly easy. Tips are drain oil first from gearbox or you end up covered in it!! Also try and get it as high as possible on axle stands. 2 People make it easier to move the gearbox. I've also changed the clutch on my 325i on the drive and did that on my own, but spent 2-3 hours trying to lift the box high enough and get the right angle, 2 people make it sooo much easier!

Here's a brief list of how I did it.
1. Disconnect battery
2. Drain gearbox oil.
3. Undo drivers side center bearing support on drive shaft
4. Undo lower wishbone bolts and pull outwards remove driveshafts from gearbox
5. Remove air box, and other items from engine bay above gearbox.
6. Remove starter bolts and bolts round gearbox to engine.
7. Support engine on jack and undo gearbox mounting to subframe
8. Lower engine slightly, and slide gearbox off shaft, support the weight of it.
9. Place gearbox on floor and have a brew.
10. Refitting is reverse order except move swearing trying to lift it up!!
 
Each vehicle is different, have a look at a decent manual (not haynes?!) and see if you think you can do it. £200 labour plus parts is about right for a box rebuild.
 
One of the lovely members on here (Confused) helped me pull the gearbox out of my Galant when a bearing went, while it wasn't hugely difficult, it's not something I would want to attempt without someone who knows what they are doing (he'd already done a couple before) and as said, they are pretty heavy!

If you've got a mechanic mate, who's a bit clued up, then by all means go for it, be prepared to make a weekend of it though!
 
As said every car is different, but if you get the workshop manuals and give them a good read and do your research FULLY before doing it, it should be no problem.

I had NO clue about gearboxes, but recently did my clutch, flywheel, box off, and a full box rebuild, cleaning all the syncros and replacing all the bearings in the casings.

All that and I no clue what a box looked like inside or even how it worked!

I took my time, and thankfully someone on the car specific forums had done a pictorial guide to replacing the bearings, making things so much easier!

Unfortunately, I now have to do it all again, as the LSD has given up the ghost, but when it was all done, ah man, the satisfaction, and it drove the best it had ever driven.

Clutch was beautifully smooth, box was perfect!

Do it.

The fact its such a big ass van you would hope might make it easier, although being French anything is possible!

I would advise perhaps doing it on ramps, unless you have a really really secure way of leaving the van up high enough to get the box out on the ground.

Happy days when all is said and done though.

EDIT:- I see the instructions above, seems quite straightforward.
 
Wicksta said:
And there is nothing that smells worse than gearbox oil!
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Never ever comes out either. Poured a load of the stuff down my Ford Motorsport jacket taking the gearbox out of an AE86 years ago. Still makes me angry thinking about it!
 
If the motor is RWD it's a peace of ****, If the motor is FWD it depends on the motor & how much room there is, Either way FWD is a pain in the ****.
 
Done three gearbox replacements on my drive now, two FWD and one RWD. Not at all difficult as long as you work methodically, and to any instructions you may have. Make sure the car is well secured on stands, and you should be good to go.
 
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