UK-POLOS.NET - THE VW Polo Forum

help!

Hitting a bit of a make-or-break impasse on the gearbox and i need experienced advice --- ive set my deadline for this time next week, if its not done, the car goes for spares/repair in whatever state its in.

bit long but the details are neccessary

So far i have
* got all five bolts off
* removed starter motor
* removed clutch, speedo, and reversing light cables
* removed linkage
* removed clutch cover panel
* removed top mount
* got engine and box both supported from underneath

not necessarily in that order....

wasnt able to properly undo the through-bolt for the rear mount (or was i?) so i've simply taken the whole thing off the chassis ... BUT its still connected to the gearbox ... can't see how to remove it whilst its still in the car as there are simply too many obstacles to getting a spanner or socket in to undo the 2 or 3 bolt-AND-nut pairs attaching them on

don't think that's my problem though

the whole thing has shifted right about an inch so far, and it's just exposing the toothed rim of the flywheel and maybe a little bit of the clutch assembly - it's not fully exposing it however, i can't yet drop it down.

the box feels very loose in all directions up/down (on the jack) & forwards/backwards (by hand) as far as i dare to move it (not much), but i cannot for the life of me get it to pull "off" the engine fully so it can be dropped down.
i thought previously that the rear mount was catching, but that's fairly free to move now (but for the rear brake pipes, which arent too much of a bother). seems it might be catching on one of the coolant pipes, the whole arrangement being such that either the mount is free, or the bolt point thats catching is, but not both together?

get the notion that its something else entirely, like the clutch isnt dismounting from the input spline properly or something... or perhaps the small amount of shift its already encountered (esp. when undoing the mounts) has mashed it up and locked it all together?

even so im not sure if theres enough free space chassis-wise to move it sideways across the engine bay to have it clear of the engine so it can go down. the 4-speed plastic splashguard is still clipped in place but its almost certainly not that, as its flexible.

again, help!

For a start you're making things very difficult by not removing the rear mount.. it can be done, it's a bit fiddly but not impossible.
I suspect you'll find the actual problem is that the driveshaft flange isn't clearing the flywheel. I have yet to work out how to get round this, but there's a certain angle you can get it to where it just magically clears. Try dropping the engine down so it's angled towards the floor, it makes it easier.

i think i remember someone saying about a flange before, but they were a bit vague....... so all i can say to you on that front is ....

the what?!

(seriously, what is this thing?)

i know i'm going to have to drop it down some, for some reason being able to do that (the remaining connected mount is after all pretty flexible) skipped my mind completely. should make getting it off with the rear mount in place somewhat easier too.

just thought i'd drop the pics in from the porka thread i also had along these lines - this one will actually be a lot "cleaner" as i can do it all in one go and cut out any nonsense.
edit: removing profanity that somehow got past the swear filter
EDIT 2 : AS I'VE NOTED on porka, though it may look dodgy at first, there are a solid pair of stands under the suspension strut anchor point - if they can't hold the car up nothing can. I HAVEN'T gone crazy and lifted the entire thing up by the sump and gearbox (especially is it would be one through-bolt and one locator bolt keeping it up, if i had)


my ghetto alternative to a service pit or lift ramp


theres the thingy... how far i've moved it so far


the evil rear-mount bolts that can't be undone with current toolage ///// the starter damn near fell off once it's bolts were loosened, but i've tested putting it back on and it's no trouble


i'm still not 100%, but it looks and feels like good clearance ///// aw great, now i need to find a replacement hot air pipe, and all i know on the subject is that halfords ones are crap!


i'm just hoping that the lack of clearance seen here doesn't mean a 5-speed won't fit at all...

john peel day on radio one has been good, but i John Peel Day! think they were Celebrating John Peel's Life laying it on Text Your John Peel Memories Now! just a trifle I'm sure John Peel is having a great time at God's right hand now thick. Luckily annie nightingale is an old skooler like the good man himself, and recognises the proper spirit of things is to let the music do the talking. it's been the best set of the day... different, banging, and largely uninterrupted except when necessary