Nina Caldwell
Stripping down a gearbox is a complex process that requires a lot of patience and a certain level of expertise. It is important to have the right tools and safety measures in place, such as a floor jack, engine hoist, and a breaker bar to separate and lower the transmission safely. The process involves removing the differential, speedometer housing, and various gears and shafts, as well as disconnecting driveshafts and battery and airbox removal. It is recommended to have assistance when attempting this task, as it involves moving heavy components and can be challenging to do alone.
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What You'll Learn
Disconnect the driveshafts from the gearbox
Disconnecting the driveshafts from the gearbox of a Golf can be a challenging task and may require some specialized tools. Here is a step-by-step guide to help you through the process:
Firstly, it is important to ensure your safety and the stability of the vehicle. Place the car on a flat, level surface and engage the parking brake. It is recommended to chock the wheels and use jack stands for added safety. You will need to raise the car and safely support it to gain access to the underside of the vehicle.
Before disconnecting the driveshafts, it is crucial to drain the gear oil to avoid spills. Place a container under the drain plug and remove it to allow the oil to drain completely. Once drained, you can proceed with disconnecting the driveshafts.
There are different approaches to removing the driveshafts, and the specific method may depend on your Golf model. Some people suggest that the driveshafts can be wiggled out of the hubs without fully disconnecting them from the gearbox. This approach may work if you are dropping the gearbox from underneath the vehicle while leaving the engine in place. However, others have noted that removing the gearbox without disconnecting the driveshafts can be challenging, especially for the Mk1 Golf.
To completely disconnect the driveshafts from the gearbox, you may need tools like a large flat chisel or a ball joint splitter. First, release the drive shaft from the wheel hub. Then, with something placed under the end of the shaft to catch any remaining oil, use sharp, short pulls to disconnect the shaft from the CV joint. You may need to turn the shaft while applying force. Alternatively, you can use a chisel to lever the shaft out with sharp, jerky movements.
Once the driveshafts are disconnected, you can proceed with removing the gearbox or performing other necessary repairs. Remember to refer to a trusted repair manual or seek advice from a qualified mechanic if you are unsure about any steps in the process.
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Remove the speedo housing
To remove the speedo housing on a Land Rover, you must first access the speedo drive gear. You can do this by removing the middle seat or cubby box and the panel to reach the transfer box from inside the car. Undo the two 10mm nuts holding the speedo cable in place and then remove the stud from the gearbox. Once you have removed the housing, the speedo drive gear will come out with it.
If your speedo has stopped working, it is most likely the speedo cable that is faulty and should be replaced first. If this does not fix the issue, you will need to check if the speedo drive gear is turning the inside of the cable. Disconnect the cable at the speedo end and secure it in view. Drive the car for a few yards and if the speedo drive gear is turning, then your speedometer is broken.
If you are removing the speedo housing on a Golf TDI 1.9 MK4 6, you will need to remove the gear selector shaft for the box to open. Remove the rubber cover from the shaft, then remove the two 13mm bolts and the holding bracket they attach to. Remove the three 13mm bolts towards the bottom of the box. These bolts hold the housing in place.
Once you have removed these bolts, the selector shaft should be loose and move around easily. You can now get the housing out. Pry it away from the box with a flat-blade screwdriver. The shaft may become very stiff and the housing may seem like it will not come out. You need to pry it out firmly until it comes out. Once you have done this, you should be able to wiggle the shaft up and out of the box.
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Remove the differential
Removing the differential is a crucial step in stripping down a gearbox. Here is a detailed guide on how to do it:
Firstly, ensure you have removed the speedo housing from the gearbox. This will grant you access to the differential. Next, you will need to undo the first motion shaft nut and the pinion gear nut. These nuts are usually very tight, so you may need to turn the gearbox upside down and ask a helper to stand on it while you undo them. Remember to tap back the locking tabs first! Once these nuts are removed and safely stored, return the gearbox to the neutral position by moving the syncro hubs back to their original places.
Now, you can remove the differential pinion gear. It should come off easily when pulled. After this, undo the nuts holding the bearing retaining plate and remove the plate itself, along with the plate holding the reverse gear idler shaft. With these components removed, you can access the differential. To remove it, simply undo the bolts that secure the differential side covers and remove them. You may need a soft-faced hammer here as they can be stubborn. Be cautious when removing the cover on the clutch side of the gearbox, as it also secures the spring and plunger for the gear selector rod. Ensure you carefully remove the spring, plunger, and ball.
With the differential exposed, you can now lift it out. However, there are a few more components to remove first. The axle flanges are held in place with Allen screws, which must be removed. Additionally, there are two bolts inside the case that must be removed before splitting the case; otherwise, you risk damaging the internal plastic lubrication plumbing assembly. Once these bolts are removed, carefully separate the case halves.
With the differential removed, you can now fully disassemble the gearbox, clean or replace components, and then reassemble the unit with fresh gearbox oil. Remember to always keep the workspace clean and ensure no dirt enters the exposed gearbox.
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$23.17
Remove the laygear shaft
Removing the laygear shaft can be a challenging process. Here is a step-by-step guide to help you through the process:
First, make sure you have removed the differential pinion gear and the plate that holds the reverse gear idler shaft in place. These steps are crucial before attempting to remove the laygear shaft.
Next, you will need a suitable drift and a long piece of coat-hanger wire. As you begin to drift out the laygear shaft, carefully push the wire down the centre to keep the thrust washers in place. It is important to allow the laygears to move to the bottom of the casing during this step.
If your laygear shaft is particularly stubborn and refuses to budge, you may need to apply some heat to the case. This will help loosen things up, and the laygear shaft should then come out more easily.
Once the laygear shaft is out, you can proceed to lever off the old bearing from the end of the shaft. This step may require some force, and you can use a rubber mallet or a similar non-destructive tool to tap the gears and pop off the bearing.
It is worth noting that some experts suggest that a tight fit between the layshaft and the bearing is not necessary. However, if you find that it is too tight, you can ease down the end of the shaft with emery tape to create some wiggle room.
By carefully following these steps, you should be able to successfully remove the laygear shaft from your golf gearbox.
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Use a breaker bar to secure the box
A breaker bar is a crucial tool for any DIYer working on their car. It is designed to increase power by providing more leverage and, therefore, more torque for undoing hardware with a high torque value or hardware that is particularly stuck.
When removing a golf gearbox, a breaker bar can be wedged above the engine and box to secure the box and prevent it from falling. To do this, first attach a socket to the breaker bar and then attach this to a nut or bolt above the engine and box. Ensure that the socket is firmly and securely attached, otherwise, it may slip and round off the head, requiring a lengthy extraction process.
If you do not have a breaker bar, an old pipe can be used as a substitute. However, be careful as this could slip and cause harm to you or the car.
Once the breaker bar is securely in place, you can then get underneath the wheel arch and wiggle the box off the engine, using a jack to lower it down slowly.
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Frequently asked questions
Disconnect the driveshafts from the gearbox. It is also possible to wiggle the gearbox away with the driveshafts still in the hubs.
You will need a complete socket and wrench set, two jacks, flathead and Philips screwdrivers, and a pry bar.
The first step is to remove the differential by undoing the bolts that secure the diff side covers and removing them.
Lock the gearbox into first and fourth gears by rotating the selector rod anti-clockwise. Then, move the syncro hub and the hub to their original positions.
Tap the end of the mainshaft with a suitable drift to access the main double roller bearing. Use a drift to carefully tap the bearing out from the gearbox casing.
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