306 gearbox

Conchurl

hi im trying to take out the gearbox out of my old 306 as the the clutch is going in my new 306 and the clutch was only put into the old 306 6 months before coming off the road. i am having problems splitting the gearbox from the engine i have the drive taken out on the passengers side. do i need to take out the piece that i circled in red or from the pics can ye see anything else that should be taken out. the photos are on image shack the link is below.

http://imageshack.us/g/442/imag0044qv.jpg/

johnayo

Looking at those pics, you are splitting the gearbox. The bolts holding the bell housing are further in. You need to put all those bolts back in before you proceed further.

Conchurl

could you explain it in a bit more detail please

johnayo

You are dismantling the gearbox with the bolts you are removing.what you need to is to remove the bolts that hold the bell housing to the engine. If you look at the pic with the red circle, the bolts will be at the left of this as you look at it.

Ferror

These videos off youtube are fairly good, it's for a diesel 1.9 xud 306, but the hdi and tu engined cars have a similar setup.

http://www.youtube.com/watch?v=znGv4LlTYTY

http://www.youtube.com/watch?v=5hQjA6KGQts

Best of luck...

Conchurl

Ferror wrote: »

These videos off youtube are fairly good, it's for a diesel 1.9 xud 306, but the hdi and tu engined cars have a similar setup.

http://www.youtube.com/watch?v=znGv4LlTYTY

http://www.youtube.com/watch?v=5hQjA6KGQts

Best of luck...

i have been watching them i have done everything except the bit i have circled in red and the drivers side drive shaft ( he said you dont have to take this off) and ideas as to what is keeping it on all the nuts and bolts are opened.

2012 Rio

Yeah mate. Your splitting the wrong place. Slite it at the enging/bell housing.

Bad news i'm afraid now - since you've basically opened the gearbox, the gasket will be brokern and it will leak even if you do up those bolts again. Your gonna have to take the box out completely now and split it on the bench and put in a new gasket. Thats in addition to thoughoughly cleaning the gasket mating faces.
Unfortunately reassembling a gearbox is not really a job for a DIYer unless you really know what your at - there's a lot of clearances to be set and adjusted using shims. Just slapping it together could result in a very notchy or inoperable gearchange and no offence mate, you don't exactly seem to know what your at.:o:o
Plus, I hope you haven't let any dust or grit fall in to the inside of the box - that will screw up the bearings in no time.
Your best way out of this now is probably to buy a second hand gearbox from the scrappy or else have a professional reassemble the gearbox as it has to be almost completely dismantled to to a proper job on the gasket.
A full strip is kinda needed as you have to make sure no pieces of gasket that are cleaned off the case fall into the box.

A replacement gear box is probably the cheaper and faster option.

Unfortunately you created an awful lot of work for your self and cost yourself a fair bit of money by this mistake.

But it does need sorting. As I said, jsut sticking it together again won't work - it'll leak gear oil all over the place.

Conchurl

2012 Rio wrote: »

Yeah mate. Your splitting the wrong place. Slite it at the enging/bell housing.

Bad news i'm afraid now - since you've basically opened the gearbox, the gasket will be brokern and it will leak even if you do up those bolts again. Your gonna have to take the box out completely now and split it on the bench and put in a new gasket. Thats in addition to thoughoughly cleaning the gasket mating faces.
Unfortunately reassembling a gearbox is not really a job for a DIYer unless you really know what your at - there's a lot of clearances to be set and adjusted using shims. Just slapping it together could result in a very notchy or inoperable gearchange and no offence mate, you don't exactly seem to know what your at.:o:o
Plus, I hope you haven't let any dust or grit fall in to the inside of the box - that will screw up the bearings in no time.
Your best way out of this now is probably to buy a second hand gearbox from the scrappy or else have a professional reassemble the gearbox as it has to be almost completely dismantled to to a proper job on the gasket.
A full strip is kinda needed as you have to make sure no pieces of gasket that are cleaned off the case fall into the box.

A replacement gear box is probably the cheaper and faster option.

Unfortunately you created an awful lot of work for your self and cost yourself a fair bit of money by this mistake.

But it does need sorting. As I said, jsut sticking it together again won't work - it'll leak gear oil all over the place.

that is my old car that will be going for scrap soon all i want to do is get the clutch out of it to give to the mecanic so he can fix the clutch in my other car so i dont care if the gearbox is broken now as it was going before i took that car off the road. could you post a pic of where i should be splitting it.

johnayo

2012 Rio wrote: »

Yeah mate. Your splitting the wrong place. Slite it at the enging/bell housing.

Bad news i'm afraid now - since you've basically opened the gearbox, the gasket will be brokern and it will leak even if you do up those bolts again. Your gonna have to take the box out completely now and split it on the bench and put in a new gasket. Thats in addition to thoughoughly cleaning the gasket mating faces.
Unfortunately reassembling a gearbox is not really a job for a DIYer unless you really know what your at - there's a lot of clearances to be set and adjusted using shims. Just slapping it together could result in a very notchy or inoperable gearchange and no offence mate, you don't exactly seem to know what your at.:o:o
Plus, I hope you haven't let any dust or grit fall in to the inside of the box - that will screw up the bearings in no time.
Your best way out of this now is probably to buy a second hand gearbox from the scrappy or else have a professional reassemble the gearbox as it has to be almost completely dismantled to to a proper job on the gasket.
A full strip is kinda needed as you have to make sure no pieces of gasket that are cleaned off the case fall into the box.

A replacement gear box is probably the cheaper and faster option.

Unfortunately you created an awful lot of work for your self and cost yourself a fair bit of money by this mistake.

But it does need sorting. As I said, jsut sticking it together again won't work - it'll leak gear oil all over the place.

It's a while since I have one of these gearboxes stripped, but I don't remember there being a gasket between those housings. I think it was just gasket maker.
As you have already said though Any dirt getting in around this area will be a disaster.

2012 Rio

Ok then. Panic over I suppose.:)

So basically what you want to do is to go to the next joint in the driver side dierection, closest to the engine. It will be at the widest part of the bell housing. you might need to undo the starter. Undo that righ of bolts and you should, as it says in the vid, remove the cover from the bottom half of the flywheel.

Anyway, I think it's a bad idea to put a part worn clutch into your good car. Clutches are a wearing part, you always replace it with a new one.
What you are doing is comparable to putting a second hand timing belt or brake pads on your good car.
Where I worked, when a engine/gearbox had to be split, we always replaced the clutch as a matter of course, even if it was fine or even relativeley new - it's a consumable.
What you are doing is a false economy, the release bearing could be on the way out or anything, the springs could be weak or the disk worn.

A new clutch kit is not expensive anyway. I strongly advise using a new clutch kit. Definitely.

It's a while since I have one of these gearboxes stripped, but I don't remember there being a gasket between those housings. I think it was just gasket maker.
As you have already said though Any dirt getting in around this area will be a disaster.

Even so, to get a good clean surface and a proper seal with gasket maker, you'd have to strip it down. Shlapping it together "with a shot o' sillycone" is a recipie for leaks. Definitely dirt in there. One of the pics has a vicegrip down between the box castings and I think another pic shows cobwebs dangling into the gearbox.

johnayo

Conchurl wrote: »

that is my old car that will be going for scrap soon all i want to do is get the clutch out of it to give to the mecanic so he can fix the clutch in my other car so i dont care if the gearbox is broken now as it was going before i took that car off the road. could you post a pic of where i should be splitting it.

Maybe take a look from underneath the car. Look at where the the gearbox meets the engine. That's the where you need to separate it. I think there are 4 bolts on this housing.

Conchurl

2012 Rio wrote: »

Ok then. Panic over I suppose.:)

So basically what you want to do is to go to the next joint in the driver side dierection, closest to the engine. It will be at the widest part of the bell housing. you might need to undo the starter. Undo that righ of bolts and you should, as it says in the vid, remove the cover from the bottom half of the flywheel.

Anyway, I think it's a bad idea to put a part worn clutch into your good car. Clutches are a wearing part, you always replace it with a new one.
What you are doing is comparable to putting a second hand timing belt or brake pads on your good car.
Where I worked, when a engine/gearbox had to be split, we always replaced the clutch as a matter of course, even if it was fine or even relativeley new - it's a consumable.
What you are doing is a false economy, the release bearing could be on the way out or anything, the springs could be weak or the disk worn.

A new clutch kit is not expensive anyway. I strongly advise using a new clutch kit. Definitely.

a new clutch was put into this car in dec 2010 and the car was taken of the road in july 2011 ( i think) so i dont see the point in spending 100 euro on a new clutch when i have one that has only been used for a few months.

ianobrien

OP, the item circled in red is the clutch release pivot. The clutch cable was in the large circular "hole" at the other end of the bar. When you pressed the clutch pedal, that pulled the bar and it pivoted, with the fulcrum in the middle of the red circled. This then pulled back on the release bearing in the bellhousing.

johnayo

Conchurl wrote: »

a new clutch was put into this car in dec 2010 and the car was taken of the road in july 2011 ( i think) so i dont see the point in spending 100 euro on a new clutch when i have one that has only been used for a few months.

At least make sure that the release bearing is good. These had a habit of seizing and going through the pressure plate.

Conchurl

johnayo wrote: »

At least make sure that the release bearing is good. These had a habit of seizing and going through the pressure plate.

ok i will check that out.

2012 Rio

Even so, I would still strongly advise a new unit. Just as a sort of insurance. It will likely be OK but if it does fail, you'll be shelling out again to replace a clutch for a second time. false economy.

Conchurl

i have attached a pic could ye tell me if where i should be splitting it is on the left of the arrow?

johnayo

Conchurl wrote: »

i have attached a pic could ye tell me if where i should be splitting it is on the left of the arrow?

Yes that is the place.

Conchurl

johnayo wrote: »

Yes that is the place.

ok i will have another go of splitting it again tomorrow evening. i will let ye know how i get on with it.