brianconwy · Feb 28, 2019

I want to remove the gearbox on our 2003 td5. I need to drill out rivets to remove a panel by the gearstick. Will removing the round plate surrounding the gearstick itself give enough access for doing this?
Thanks
Brian

Gazbo · Feb 28, 2019

brianconwy said:
I want to remove the gearbox on our 2003 td5. I need to drill out rivets to remove a panel by the gearstick. Will removing the round plate surrounding the gearstick itself give enough access for doing this?
Thanks
Brian

Yes it should, I have removed and replaced two D1 manual boxes this way. I did make a small gantry affair that mounts on the front floors just ahead of the fully pushed back seats with a rhs beam that spanned the tranny tunnel to spread the load.
Lifting/supporting was done with a long threaded rod with a short bit of chain attached to the gearbox/transfer case assembly. The threaded rod, (16mm dia) had a nut that sat upon a small thrust bearing on top of and through the spreader making it easy to precisely raise/lower the unit to remove and replace.
After everything is unbolted you only need the front of the vehicle on ramps and a trolley jack to tilt the engine up a bit at the front, once the box is down slide it out the side from beneath.

brianconwy · Mar 1, 2019

I have bought a second hand engine hoist for lifting and lowering and an engine support beam to support the engine at the right height.

Its good to know that I only have to remove that plate.

Was the one piece of chain enough? You didn't need to attach a chain/sling to the transfer box as well?

Thanks
Brian

Gazbo · Mar 1, 2019

brianconwy said:
I have bought a second hand engine hoist for lifting and lowering and an engine support beam to support the engine at the right height.

Its good to know that I only have to remove that plate.

Was the one piece of chain enough? You didn't need to attach a chain/sling to the transfer box as well?

Thanks
Brian

The chain was only 3 or 4 links to attach the threaded rod to a bolt hole at the balance point of the gearbox assembly, all the lifting movement up and down was done with the 16mm nut and about 500 mm of 16mm threaded rod, it gave very precise positioning to extract and instal the gearbox from and to the engine.
The whole load suspended from one point so it was very maneuverable.
Your engine crane in through the door will work ok, but you may need someone to operate the crane, my system enables me to do the whole job single handed, go to woa.
If I was currently at home and I knew how to put photos on here I could show you this simple device I made, it makes the job so easy.

brianconwy · Mar 1, 2019

Thanks. I have placed a sling through the gearstick hole. I don't know if it is the balance point though. Just taking the mounts off now. Thanks.

jamesmartin · Mar 1, 2019

brianconwy said:
I have bought a second hand engine hoist for lifting and lowering and an engine support beam to support the engine at the right height.

Its good to know that I only have to remove that plate.

Was the one piece of chain enough? You didn't need to attach a chain/sling to the transfer box as well?

Thanks
Brian

i remove boxes through the tunnel opening with an engine crane very frequently, i use a chain on the top rhs stud that secures t/box to g/box, its front heavy but very level side ways

brianconwy · Mar 1, 2019

jamesmartin said:
i remove boxes through the tunnel opening with an engine crane very frequently, i use a chain on the top rhs stud that secures t/box to g/box, its front heavy but very level side ways

We have the mounts off and have started to tilt the gearbox. How far do we need to tilt? Is there an easy way to remove the plastic sound insulation cover?

jamesmartin · Mar 1, 2019

brianconwy said:
We have the mounts off and have started to tilt the gearbox. How far do we need to tilt? Is there an easy way to remove the plastic sound insulation cover?

if you have it hanging off the crane lower it down as far as you can ,remove fan cover first, the cover will then easily rotate and out t,whilist its down remove crank sensor and oil pressure connector and top rhs box to engine bolt, raise transmission and from engine bay undo top lh box to engine bolt plus the 8mm headed bolt on that side securing the steel cover plate, then raise the transmission to undo the rest and pull out the box, the good thing about an engine crane is been able to raise /lower the transmission to get better access at different parts

brianconwy · Mar 1, 2019

jamesmartin said:
if you have it hanging off the crane lower it down as far as you can ,remove fan cover first, the cover will then easily rotate and out t,whilist its down remove crank sensor and oil pressure connector and top rhs box to engine bolt, raise transmission and from engine bay undo top lh box to engine bolt plus the 8mm headed bolt on that side securing the steel cover plate, then raise the transmission to undo the rest and pull out the box, the good thing about an engine crane is been able to raise /lower the transmission to get better access at different parts

Thanks. I have removed the crank sensor when taking the starter off. Can I do damage by lowering the gearbox too much? We are still trying to remove cover. Thanks again.

jamesmartin · Mar 1, 2019

brianconwy said:
Thanks. I have removed the crank sensor when taking the starter off. Can I do damage by lowering the gearbox too much? We are still trying to remove cover. Thanks again.

no in fact box would hang with out support but watch the fan

brianconwy · Mar 1, 2019

I have taken the fan off. The cover is coming looser. Thanks.

brianconwy · Mar 1, 2019

The cover is now off. I need to remove the low ratio selector cable. Is there an easy way or is it just as rave says and remove clevis pin and c washer?

berg450 · Mar 1, 2019

brianconwy said:
The cover is now off. I need to remove the low ratio selector cable. Is there an easy way or is it just as rave says and remove clevis pin and c washer?

for me it was easy to remove clevis pin and C clip. Did it already 2 times...

brianconwy · Mar 1, 2019

We have now got the two top bolts off, so wil have a go at this clevis pin. I will try and find the oil pressure connector. How many 8mm bolts are there? I can see one on the passenger side. Thanks

berg450 · Mar 1, 2019

see this video, helped me a lot...

jamesmartin · Mar 1, 2019

brianconwy said:
We have now got the two top bolts off, so wil have a go at this clevis pin. I will try and find the oil pressure connector. How many 8mm bolts are there? I can see one on the passenger side. Thanks

1 8mm headed bolt
behind oil filter under manifold

brianconwy · Mar 1, 2019

jamesmartin said:
1 8mm headed bolt
behind oil filter under manifold

I have got that off. We are nnow trying to get the low ratio cable off. Just bashed my thumb. Is it better doing this after undoing the gearbox and lowering it down?

jamesmartin · Mar 1, 2019

brianconwy said:
I have got that off. We are nnow trying to get the low ratio cable off. Just bashed my thumb. Is it better doing this after undoing the gearbox and lowering it down?

i leave that connected to the lever and drop the whole lot down through the hole

brianconwy · Mar 1, 2019

berg450 said:
see this video, helped me a lot...

I have been watching this video and other posts, including an old one from brewed in the UK.

brianconwy · Mar 1, 2019

jamesmartin said:
i leave that connected to the lever and drop the whole lot down through the hole

Do you mean by undoing the four bolts on the console inside the car?

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