Post #1
Decided to undertake doing the clutch at home in stands, got everything off (IB was the worst!) and fitted new clutch kit. After ages of lifting and wiggling I got the box back up and slid it on. The fork didn't take I the bearing and now I've backed it on and off and I just can't do it. It's wasted so many hours of my life now it's painful! There must be a way that it can go on, the box isn't even sliding back on now and only goes flush using the bolts to pull it towards the block.... Can anyone help? I'm near Canterbury Kent if anyone's local?
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| Author | Subject: Refitting box after clutch change - nightmare, please help! |
 Batesy86
Regular  Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
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 Posted 14th Oct 2012 at 18:50
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Niall
Seasoned Pro  Location: Epsom Registered: 06 Jun 2012 Posts: 1,941 Status: Offline |
Post #2
it has to go on dead straight. I had the exact same problem with a mates 306. Spent hours at it and thought sod doing mine, will get KrisB to do it. His approach was get the box up into place, get under the car and wiggle like hell until it pops in! worked well! |
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Posted 14th Oct 2012 at 18:59
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dangti6
aka JKshooter  Location: Taunton, Somerset Registered: 15 Jun 2006 Posts: 10,305 Status: Offline |
Post #3
Get the box on the floor and put the clutch and bearing up to it and familiarise yourself with the movement of the fork when you move the arm. Set it in the right place and don't knock it.Removing the mounting stud from the 'box helps. ________________________________________  |
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Posted 14th Oct 2012 at 19:05
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welshpug!
Capt Pedantic  Location: Bigend, Wales. Registered: 27 Mar 2007 Posts: 25,838 Status: Offline |
Post #4
pop the speedo housing off, that also helps with locating the box.________________________________________ need a part number? get on here - http://public.servicebox.peugeot.comBring on the Trumpets. |
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Posted 14th Oct 2012 at 19:07
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #5
The speedo housing? Didn't know I could take that off. I've take the stud out as it was wrecking the inner wing. I'm so reluctant to take the box back to the floor as it was such a pain getting it back up there! It truly is a s**t job, if the fork and bearing are lined up does it pop on and hook itself or does the fork need pulling towards the bulkhead as the box butts up to the block? |
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Posted 14th Oct 2012 at 19:13
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dangti6
aka JKshooter Location: Taunton, Somerset Registered: 15 Jun 2006 Posts: 10,305 Status: Offline |
Post #6
You can leave it on, but due to it possibly fouling on the subframe when your manhandling the box, it's worth the 30 seconds undoing it tbh.Admittidly it's not a great job. Especially if you lack patience like myself. You'll here it pop on. Probably the best sound you've heard yet this year. ________________________________________ |
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Posted 14th Oct 2012 at 19:21
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #7
Ill pop that of then, are the bolts round the back engine amd bulkhead side? I will scream with delight when I finally hear that pop! |
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Posted 14th Oct 2012 at 19:25
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stan_306gti6
Forum Admin Location: Kent Registered: 18 Jan 2004 Posts: 21,768 Status: Offline |
Post #8
The speedo housing is held on with 3 bolts, I would strongly recommend this comes off it will make your life so much easier.Ideally, you need a mate to help. If I were you I would get an assistant to get underneath and wiggle the box on whilst you are up the top with a torch and small screwdriver and you can flick the fork into position through a small access hole at the top of the bellhousing as the box is being lifted on by the assistant.  It can be done on your own but it's not really a one man task TBH. ________________________________________ "Supercharged - 454.1bhp/317.5lb/ft"Peugeot 306 GTi-6 2000 (X), Moonstone  |
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Posted 15th Oct 2012 at 09:55
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #9
By speedo housing do we mean the little piece that the driveshaft goes into? Or a part of the box that the little piece bolts to? |
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Posted 15th Oct 2012 at 10:35
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dangti6
aka JKshooter Location: Taunton, Somerset Registered: 15 Jun 2006 Posts: 10,305 Status: Offline |
Post #10
Where your speedo drive plugged in to.________________________________________ |
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Posted 15th Oct 2012 at 10:39
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jonnie205
Seasoned Pro  Location: Bicester Registered: 10 Apr 2005 Posts: 4,146 Status: Offline |
Post #11
line up the fork and bearing before lifting box into car. Make sure the fork and pivot shaft and free and move easily. Lay under car and lift box onto your chest, lift box up into the bay resting on your knees if you need a break. carefull locate the input shaft in clutch without knocking bearing. at this point you can look into bell housing and watch the bearing locate as you push the box onto the dowells. make sure clucth is properly lined up before doing anything. I never remove spike or speedo housing. |
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Posted 15th Oct 2012 at 10:54
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rikky
🦔 Location: cheshire Registered: 28 Feb 2004 Posts: 26,796 Status: Offline |
Post #12
this is the housingrikky has attached the following image: ________________________________________ 306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges gti6 inlet manifold badges | 306 rear boot badges (p2/p3) winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club] |
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Posted 15th Oct 2012 at 11:01
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #13
I took that off with the driveshaft so that's fine. Ill just have to keep trying I guess but it's so hard because the weight and space is awkward along with the fork and bearing having to be precise |
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Posted 15th Oct 2012 at 16:11
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roland rat
Yeeeah Rat fans!  Location: Swansea Registered: 29 Nov 2006 Posts: 22,284 Status: Offline |
Post #14
stick bearing inplace with blu-tack or used chewing gum  |
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Posted 15th Oct 2012 at 16:20
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stan_306gti6
Forum Admin Location: Kent Registered: 18 Jan 2004 Posts: 21,768 Status: Offline |
Post #15
Have you tried getting a friend to help you yet?  ________________________________________ "Supercharged - 454.1bhp/317.5lb/ft"Peugeot 306 GTi-6 2000 (X), Moonstone |
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Posted 15th Oct 2012 at 16:21
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dangti6
aka JKshooter Location: Taunton, Somerset Registered: 15 Jun 2006 Posts: 10,305 Status: Offline |
Post #16
stan_306gti6 wrote: Have you tried getting a friend to help you yet? Not everyone has friends, you know that. ________________________________________ |
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Posted 15th Oct 2012 at 16:23
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roland rat
Yeeeah Rat fans! Location: Swansea Registered: 29 Nov 2006 Posts: 22,284 Status: Offline |
Post #17
dangti6 wrote: stan_306gti6 wrote: Have you tried getting a friend to help you yet? Not everyone has friends, you know that. Doesnt need friends when you're beating the biatches off with a s**tty stick |
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Posted 15th Oct 2012 at 16:24
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dangti6
aka JKshooter Location: Taunton, Somerset Registered: 15 Jun 2006 Posts: 10,305 Status: Offline |
Post #18
His exact words were 'Can't be dealing with potential cock blockers'. ________________________________________ |
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Posted 15th Oct 2012 at 16:26
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #19
Lol my brother came round but wasn't much use to be honest! Will a bit of masking tape be better than some bluetac or gum? |
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Posted 15th Oct 2012 at 17:56
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #20
Lol my brother came round but wasn't much use to be honest! Will a bit of masking tape be better than some bluetac or gum? |
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Posted 15th Oct 2012 at 17:56
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si_batt
Newbie Location: Warwick Registered: 01 Jan 1970 Posts: 39 Status: Offline |
Post #21
I'm assuming that given you had the box back on once, that the clutch plate is aligned centrally with the crankshaft? It's worth a check to see you haven't knocked the clutch plate off centre. A friend and I did one a few weeks back and found it a total pain too. |
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Posted 15th Oct 2012 at 18:37
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bas_306gti
Regular  Location: Eindhoven Registered: 06 Sep 2012 Posts: 108 Status: Offline |
Post #22
use a engine crane and the box will line up perfectly with the engineUse the round hole at top as lifting point  |
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Posted 15th Oct 2012 at 18:39
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #23
Yeah I centralised the drive plate but as I'm struggling now I think it may have moved. I only I had an engine crane! |
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Posted 15th Oct 2012 at 21:29
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jonnie205
Seasoned Pro Location: Bicester Registered: 10 Apr 2005 Posts: 4,146 Status: Offline |
Post #24
It can't move out of line it's clamped solid |
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Posted 15th Oct 2012 at 22:17
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Batesy86
Regular Location: Canterbury Registered: 12 Dec 2011 Posts: 138 Status: Offline |
Post #25
Even if I left the box hanging half out because my arms were ruined? |
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Posted 15th Oct 2012 at 22:47
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