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Author Subject: Gearbox Removal Issue
Eddleston

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Location: Leatherhead

Registered: 31 Jul 2012

Posts: 329

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Post #1
Hi all, again.
I've finally got round to removing my rallye engine (got a hole in it)
I'm currently trying to get the box off but having one or two issues.

The top bell housing bolt by the clutch arm pivot point is a reet bas**rd to get in to.
The spring is stopping me getting my socket allen key piece in and my normal allen key is only just able to be moved. ish. Is this normal?
Also, how many bolts am I looking for?
Was only 6 on my Hilux but already found more on this little bugger.

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Posted 14th Aug 2014 at 14:20
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rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,795

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Post #2
take spring off the clutch arm too

http://www.306gti6.com/forum/showthread.php?id=29561&page=2

^ faq, did you see that?

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306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 slam panel esso stickers | 306 yellow / orange / pension fund red side door badges
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winner of Extraction of toys from prams with outstanding vigour award 2009 [source: gti6 owners club]
Posted 14th Aug 2014 at 14:25
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Eddleston

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Location: Leatherhead

Registered: 31 Jul 2012

Posts: 329

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Post #3
So do I just pull the spring out? it only says to pull the pin out 'once the spring is removed'.

Trying not to fcuk everything up as I'm doing this on a proper budget unfortunately.

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Posted 14th Aug 2014 at 14:57
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rikky 🦔

Location: cheshire

Registered: 28 Feb 2004

Posts: 26,795

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Post #4
spring removal will be fine, it won't affect anything, should remove no problem

pin removal is another story so you can actually remove the clutch arm. it's a complete arse to get out but a set of mole grips, some heat, a hammer, etc, will help Yes

other option is to bend it up slightly so it'll turn further, thus releasing the bearing from the box and it'll pull free

the pin comes out of the front, not pushed out of the back

this is one of them times when you really need someone local who has done one before to show you, it's hard to explain

________________________________________

306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
306 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]
Posted 14th Aug 2014 at 15:02
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dangti6

aka JKshooter

Location: Taunton, Somerset

Registered: 15 Jun 2006

Posts: 10,305

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Post #5
Spring off, vice grips on pin and twist/pull. Some come out easily and some won't. If it doesn't come free before your patience wears thin, bend arm up as a last resort.

Celebrate with a beer but don't get too comfy. Getting the release bearing lined up when refitting can be fiddly.

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    • Posted 14th Aug 2014 at 15:22
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    Eddleston

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    Location: Leatherhead

    Registered: 31 Jul 2012

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    Post #6
    OK, fair enough.

    It says all the bolts round to 7, then just 9 & 10.

    Is this accurate?

    I've got 9...
    Can't un-do the mount till tomorrow though as I've had to order in a deep 18mm socket.

    Where it says 17s on your guide mine are all bloody 16s Thumbs down

    and 18mm gearbox mount Thumbs down Thumbs down

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    the zombie apocalypse started long ago, only no-one realised most can talk and drive
    Posted 14th Aug 2014 at 15:35
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    rikky 🦔

    Location: cheshire

    Registered: 28 Feb 2004

    Posts: 26,795

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    Post #7
    not my guide! but wouldn't surprise me with peugeot using odd bolts LOL

    ________________________________________

    306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
    306 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]
    Posted 14th Aug 2014 at 15:49
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    Eddleston

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    Post #8
    Well thanks for that so far, the pin and spring slid out in one happy slide Thumbs up With some force lol.

    I'm now left with the bastid bellhousing bolt round the back near the gear linkage. No combination of my sockets or spanners can get onto it. Typical!
    But now the rain's here that's me stopped for a while. Coffee time! Thumbs up

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    the zombie apocalypse started long ago, only no-one realised most can talk and drive
    Posted 14th Aug 2014 at 16:12
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    rikky 🦔

    Location: cheshire

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    Post #9
    lucky on the pin! every single one i've done it's been a grinder job or oxyacetylene torch on it. have cut the top arm off once before and tackled it off the car with a drill. you were lucky

    ________________________________________

    306 rallye reproduction decals (full sets/individual decals) | 306 b-pillar textured vinyl weatherstrips
    306 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]
    Posted 14th Aug 2014 at 16:13
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    stan_306gti6 Forum Admin

    Location: Kent

    Registered: 18 Jan 2004

    Posts: 21,768

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    Post #10
    The bellhousing bolt you are talking about at the top next to the clutch release arm should be a 16mm headed bolt.

    It also holds on the 'tray' which the crank sensor sits on. If it's an Allen head as you are saying then someone has been in there before and not put the right bolt back in the right hole...

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    Posted 14th Aug 2014 at 20:28
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    fatlapit

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    Location: STOCKSFIELD

    Registered: 02 Nov 2010

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    Post #11
    Just take off the slam and rad etc. Leave the engine and box connected and pull it out the front plus when you come to rebuild its easier to put the gearbox back on when its out the car.

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    Posted 16th Aug 2014 at 10:25
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    fatlapit

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    Post #12
    Allen bolts are for starter motor

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    Posted 16th Aug 2014 at 10:26
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    bigbadbowen

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    Location: Winchester

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    Post #13
    There are 2 Allen bolts on the back of the gear box that go the opposite way to the 16s think they are 8mm but as said it's easier to take the whole lot out as one ! Remember to remove battery tray and gear box mount it's also easier to remove the big threaded mount off the box as well
    Posted 16th Aug 2014 at 12:37
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    Eddleston

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    Registered: 31 Jul 2012

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    Post #14
    Well, I decided to remove everything before realising it was probably a good idea to just remove the lot together. Roll eyes

    So now I'm left with this stopping the box going back on, so I can't lift it all together. Crazy


    See that lovely bar through the drive shaft hole?
    What is it? I can't even get my hand in anywhere to get hold of it.

    This is turning out to be a bit of a ball ache!

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    the zombie apocalypse started long ago, only no-one realised most can talk and drive
    Posted 18th Aug 2014 at 12:02
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    Eddleston

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    Registered: 31 Jul 2012

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    Post #15
    fatlapit wrote:
    Just take off the slam and rad etc. Leave the engine and box connected and pull it out the front plus when you come to rebuild its easier to put the gearbox back on when its out the car.


    I've found the two bolts on the top cross member but where are the other two? can't find em even if i get my head right in the wheel arch.

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    the zombie apocalypse started long ago, only no-one realised most can talk and drive
    Posted 18th Aug 2014 at 12:01
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    welshpug!

    Capt Pedantic

    Location: Bigend, Wales.

    Registered: 27 Mar 2007

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    Post #16
    that's just the shaft for the planet gears, its meant to be there and wont stop you fitting the gearbox.

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    need a part number? get on here - http://public.servicebox.peugeot.com

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    Posted 18th Aug 2014 at 12:42
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    Eddleston

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    Location: Leatherhead

    Registered: 31 Jul 2012

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    Post #17
    But it surely shouldn't be sat where the drive shafts were... Unsure

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    the zombie apocalypse started long ago, only no-one realised most can talk and drive
    Posted 18th Aug 2014 at 12:50
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    dangti6

    aka JKshooter

    Location: Taunton, Somerset

    Registered: 15 Jun 2006

    Posts: 10,305

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    Post #18
    Eddleston wrote:
    fatlapit wrote:
    Just take off the slam and rad etc. Leave the engine and box connected and pull it out the front plus when you come to rebuild its easier to put the gearbox back on when its out the car.


    I've found the two bolts on the top cross member but where are the other two? can't find em even if i get my head right in the wheel arch.


    The front bumper is held to the slam panel with 4 studs. 10mm nuts. 2 either side.

    The slam panel is held to the car with 2 13mm bolts at the top by the wings and 2 studs with 13mm nuts near to the front bumper fixings.

    You can just undo the slam panel fittings and remove it with the front bumper still fixed - and the lights for that matter.

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    • Posted 18th Aug 2014 at 13:02
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    welshpug!

    Capt Pedantic

    Location: Bigend, Wales.

    Registered: 27 Mar 2007

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    Post #19
    Eddleston wrote:
    But it surely shouldn't be sat where the drive shafts were... Unsure


    they all have them, nothing at all wrong there, driveshafts dont go all the way through

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    need a part number? get on here - http://public.servicebox.peugeot.com

    Bring on the Trumpets.

    Posted 18th Aug 2014 at 13:05
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