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Old 14-09-08, 12:50   #1
...joshwa
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Gearbox wont drop out!!!

Ok so I am in the process of doing a manual conversion in my calais. .
I have taken all the bolts around the bellhousing out and taken the crossmember off. The box is sitting about 10cm off the block now and I can see the flexplate etc etc but it just WONT budge from there. It is on a massive angle downwards and im getting scared that it is going to bend something. . . Why wont it just pop out??
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Old 14-09-08, 12:53   #2
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have you undone all the convertor bolts?
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Old 14-09-08, 12:54   #3
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hey mate have you undone the torque converter + (4 bolts to flexplate)?
Makes the job alot more difficult trying to take it out with the converter still bolted up.
usually once the bellhousing bolts are out it will slide all the way back as it has nothing to hold it there!
good luck man feel for ya
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Old 14-09-08, 12:57   #4
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alright. . nah i havnt undone the converter bolts. . I thought the gbox would just slide out then I could undo them then?? Anyway ill give that a go and let you know soon how it goes
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Old 14-09-08, 13:09   #5
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itll be out in half an hour now you watch haha goodstuff!!
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Old 14-09-08, 13:18   #6
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When i did my manual conversion i had the exact same problem.

It was literally hanging out, but wouldn't drop.

Undid the converter bolts and it fell on the ground lol
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Old 14-09-08, 13:33   #7
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alright. I am trying to undo the converter bolts but they are done up so tight when I try it just spins around. I cant work out anywhere where I could wedge something in to stop it.
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Old 14-09-08, 13:36   #8
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get a socket and a ratchet on the balancer and get some one to hold it whilst u undo the torque bolts
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Old 14-09-08, 13:43   #9
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Originally Posted by Sic_VL_Ex
get a socket and a ratchet on the balancer and get some one to hold it whilst u undo the torque bolts

That works! ^^^^^
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Old 14-09-08, 14:05   #10
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make sure you use a single hex socket so you dont round off the heads of the convertor bolts.

Last edited by 88_vl_bt1; 14-09-08 at 14:14.
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Old 14-09-08, 14:06   #11
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ok. excuse my ignorance but where is the balancer??
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Old 14-09-08, 14:09   #12
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lol, i dont think you should be doing this manual conversion. its the pulley at the front of the motor - the one at the bottom that all of the belts run off
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Old 14-09-08, 14:15   #13
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yeah thats what I thought. But some bloke said to hold the balancer with a ratchet and then undo the flexplate bolts. . I was wondering how in the world I was going to hold both. .

Mybad I just re read the post :P
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Old 14-09-08, 14:28   #14
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put something under the box (a jack) so it dont fall on you...

have you undone your shifter, wiringand all the rest too?
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Old 14-09-08, 16:00   #15
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any bet you havent undone the shifter
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Old 14-09-08, 17:14   #16
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yep shifter is out, drilled the rivets out, pedal box is out, steering column is out, wiring is out, dash is off. . and now, the gearbox is out . . yeah i put this wooden box under the gbox with a tunne of old rags to soften the fall, worked pretty well. . Now I have to get the bush out of the spigot which I have no idea how to, I have tried everything!! and i'm also replacing the oil seal while the box is off. .

Any ideas on getting the bush in the spigot off?
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Old 14-09-08, 18:35   #17
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Quote:
Originally Posted by ...joshwa
yep shifter is out, drilled the rivets out, pedal box is out, steering column is out, wiring is out, dash is off. . and now, the gearbox is out . . yeah i put this wooden box under the gbox with a tunne of old rags to soften the fall, worked pretty well. . Now I have to get the bush out of the spigot which I have no idea how to, I have tried everything!! and i'm also replacing the oil seal while the box is off. .

Any ideas on getting the bush in the spigot off?

Spogot bush with and auto thats the crank mate.. i have only seen manuals have a spigot bush, which make sure you put one in !!! Otherwise your box will last sweet F.A.. And before you put your manual box back in, bash the floor up in the turret tunnel as it will make your life so much easyer... (About in the same spot where your foot rest is, on the inside near you pedals) As manual and auto foor pans are slightley different, the manual has more room in tunnel. (hence the foot rest in the auto and not in the manual) Hope that helps.. ohh and if you give the floor a real good smashing make sure you bash the foot rest back over, as i smashed mine so much the foot rest wouldn't let me get the clutch to the floor !!
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Old 14-09-08, 19:21   #18
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hmmmmm. i was using this as a general guide
http://www.calaisturbo.com.au/showthread.php?t=146235
and it says to take it out??



Theres a pic, Im talking about the thing in the middle of the spiggot. . One other thing, I am replacing the oil seal so I imagine I have to take the silvery surrounding off, which I have tried to do by undoing every bolt that surrounds it, however it wont budge ??

Last edited by ...joshwa; 14-09-08 at 19:32.
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Old 14-09-08, 19:39   #19
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there may be studs or dowels on the rear main seal plate that go thru the sump. might help if you could get your hands on a gregory's manual or similar vl work shop manual.

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Old 14-09-08, 20:09   #20
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dont forget to change the backing plate to the manual one, and you got manual flywheel bolts?when you put man box in jack up the front of the engine to tip it back to make the box go in easier. yes the spigot bush has to come out and fit the manual one
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Old 14-09-08, 20:17   #21
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ahhh thats what I forgot to get, a manual backing plate, DAM! And yep i got manual flywheel bolts and a freshly machined flywheel along with a brand new clutch.
I bought a manual spigot bush from repco but it is much thinner than the auto one, and will nearly fit inside the auto spigot bush ??
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Old 14-09-08, 20:37   #22
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no the auto has to come out!!!
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Old 14-09-08, 20:38   #23
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good luck getting the auto one out lol.
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Old 14-09-08, 20:45   #24
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fill the hole with c4 and that should move it
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Old 14-09-08, 20:55   #25
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greatt. I tried drilling 2 little holes in the bush and putting some wire through there to pull it out, and the wire snapped. . this is going to be a fun week
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