Brenton 86
28th July 2006, 11:17 PM
Since breaking another box, i thought i should grab a camera an do a write up. Ideally a work pit or hoist is best but since this is diy, only chassis stands are used.
Get out ya broken pos and put in on stands. I would suggest using four stands as the car needs to be quite high to slide the boxes in an out.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110878.jpg
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110879.jpg
Then begin removing the interia surround on the shifter, four screws on the centre console than two on the plactic side pieces, then the head unit panell.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110880.jpg
Then pull the plastic surrounding from the shifter.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110881.jpg
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110882.jpg
Then unscrew the 4 brass 10mm brass bolts, then pull off the rubber boot. Unwind the knob on the stick http://www.ae86drivingclub.com.au/forums/emoticons/wink.gif. Then unbolt the four 12mm bolts fastening the shifter to the gearbox. This will detatch the shifter. This comletes the interia.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110884.jpg
Undo the drain plug, 14mm, an let drian while attending to the tailshaft.
Remove the tailshaft, four 12mm nuts/bolts connect it to the diff flange. Also two 14mm bolts will fix the carrier bearing if ur using a conventional 2-piece shaft.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110885.jpg
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110886.jpg
Then slide out the tailshaft spline from the gearbox
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110887.jpg
Next task is the clutch slave cylinder, two 12mm bolts then sit it on the exhaust to keep it out of the way
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110888.jpg
Next remove the starter motor from the bellhousing but before you do this disconnect the postive terminal on the battery, as when the starter is unbolted it will touch the engine mount an spark, an scare the shit out of you if you dont. two 15 or 14mm bolts.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110889.jpg
Next remove the speedo sender, reverse light wires and the earth.
Then start to unbolt the bellhousing from the engine they are all 17mm bolts. Start with 2 on the top, you can get them from the engine bay against the firewall. Looks wierd but here they are:
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110890.jpg
Then crack an loosen the bottom bolts but don't undo them.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110891.jpg
Then place a floor/garage jack under the box an raise it to take the weight of the box, then undo the gearbox cross member:
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110892.jpg
Then undo the last bottom bellhousing bolts, the box will then be sitting on the spline in the clutch and the jack. You will then need to pull out ya guns out http://www.ae86drivingclub.com.au/forums/emoticons/wink.gif and heave the box backward to get it out of the spline an just on the jack, then lower the box:
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110894.jpg
^^^Congradulations^^^ u have pulled out ur broken box http://www.ae86drivingclub.com.au/forums/emoticons/tup.gif now curse at the thought ur only halfway.
*knock knock* its dimitri with ur new box just in time yea yea
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110896.jpg
Now dimitri informs me that when buying a t-50 insure that you get the bellhousing aswell as there IS a reason that u shouldnt just transfer ur old onto the new box, but meh wot does he know ay http://www.ae86drivingclub.com.au/forums/emoticons/wink.gif Its gonna break in bout 3 months anyway...
Then unbolt the bellhousing from the old shagged box, 14mm i think, then the four inner bolts 12mm. Pull off the throw-out bearing and clutch fork clips. Then pull off the bellhousing an remove the old gasket, make sure not to lose the loose bearing ring!!. Then gasket goo the back of the bellhousing an bolt it to the box. Then gasket goo the front plate really good as it will leak if u dont.
(goo is copper in the centre before the plate is attached)
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110898.jpg
Then the new box is ready to be placed in the car, just repeat the above directions in reverse. I hope this helps someone http://www.ae86drivingclub.com.au/forums/emoticons/smile.gif
remember diy ftw!!!!!
Get out ya broken pos and put in on stands. I would suggest using four stands as the car needs to be quite high to slide the boxes in an out.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110878.jpg
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110879.jpg
Then begin removing the interia surround on the shifter, four screws on the centre console than two on the plactic side pieces, then the head unit panell.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110880.jpg
Then pull the plastic surrounding from the shifter.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110881.jpg
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110882.jpg
Then unscrew the 4 brass 10mm brass bolts, then pull off the rubber boot. Unwind the knob on the stick http://www.ae86drivingclub.com.au/forums/emoticons/wink.gif. Then unbolt the four 12mm bolts fastening the shifter to the gearbox. This will detatch the shifter. This comletes the interia.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110884.jpg
Undo the drain plug, 14mm, an let drian while attending to the tailshaft.
Remove the tailshaft, four 12mm nuts/bolts connect it to the diff flange. Also two 14mm bolts will fix the carrier bearing if ur using a conventional 2-piece shaft.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110885.jpg
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110886.jpg
Then slide out the tailshaft spline from the gearbox
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110887.jpg
Next task is the clutch slave cylinder, two 12mm bolts then sit it on the exhaust to keep it out of the way
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110888.jpg
Next remove the starter motor from the bellhousing but before you do this disconnect the postive terminal on the battery, as when the starter is unbolted it will touch the engine mount an spark, an scare the shit out of you if you dont. two 15 or 14mm bolts.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110889.jpg
Next remove the speedo sender, reverse light wires and the earth.
Then start to unbolt the bellhousing from the engine they are all 17mm bolts. Start with 2 on the top, you can get them from the engine bay against the firewall. Looks wierd but here they are:
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110890.jpg
Then crack an loosen the bottom bolts but don't undo them.
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110891.jpg
Then place a floor/garage jack under the box an raise it to take the weight of the box, then undo the gearbox cross member:
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110892.jpg
Then undo the last bottom bellhousing bolts, the box will then be sitting on the spline in the clutch and the jack. You will then need to pull out ya guns out http://www.ae86drivingclub.com.au/forums/emoticons/wink.gif and heave the box backward to get it out of the spline an just on the jack, then lower the box:
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110894.jpg
^^^Congradulations^^^ u have pulled out ur broken box http://www.ae86drivingclub.com.au/forums/emoticons/tup.gif now curse at the thought ur only halfway.
*knock knock* its dimitri with ur new box just in time yea yea
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110896.jpg
Now dimitri informs me that when buying a t-50 insure that you get the bellhousing aswell as there IS a reason that u shouldnt just transfer ur old onto the new box, but meh wot does he know ay http://www.ae86drivingclub.com.au/forums/emoticons/wink.gif Its gonna break in bout 3 months anyway...
Then unbolt the bellhousing from the old shagged box, 14mm i think, then the four inner bolts 12mm. Pull off the throw-out bearing and clutch fork clips. Then pull off the bellhousing an remove the old gasket, make sure not to lose the loose bearing ring!!. Then gasket goo the back of the bellhousing an bolt it to the box. Then gasket goo the front plate really good as it will leak if u dont.
(goo is copper in the centre before the plate is attached)
http://www.ae86drivingclub.com.au/dcimages/4/8/4/3/110898.jpg
Then the new box is ready to be placed in the car, just repeat the above directions in reverse. I hope this helps someone http://www.ae86drivingclub.com.au/forums/emoticons/smile.gif
remember diy ftw!!!!!