ALSO... 'RAISING A VAN & THEREFORE ENABLING D.I.Y A LOT !!!"
Tools. HI LIFT TROLLEY JACK. 4 AXLE STANDS .. If they are 'Domestic' axle stands then cut to size 4 heavy duty timber blocks.
Breaker bar/ Impact Wrench. 21 mm deep reach impact socket . And all the usual stuff
Purchase a tin of WD40 with the FLEXI HOSE . Try to find the time to apply to the following areas in advance. Combined with timing of application whilst on the job.
1. Park on level ground.
Using a Breaker bar or impact wrench 'Break' Front Wheel Nuts, Rear Wheel Nuts , 4 Gearbox Subframe Nuts & Bolts , Prop shaft to Gearbox Bolts. Apply WD40 into the 'breaks'.
ALSO CONSIDER WHAT JOBS YOU MIGHT END UP DOING.. (WHEEL BEARINGS? HALF SHAFTS?) 'BREAK' AS REQUIRED ON THE GROUND
Raise the rear of the vehicle and support with 'C' shaped or adequate 'V" shaped axle stands. On the axle !
Try to push the Van over.
Move to the front of the vehicle & clean the underside of the gearbox subframe so it's free of any grease or oil
Trolley jack placed under the centre of gearbox subframe (With a contact sheet of rubber) . Raise the front of the Vehicle.
Support the vehicle on axle stands (Ideally more of a 'T' shape or low 'V' shape. ***
*** THIS IS SUPPORTING THE VEHICLE BODY 'CHASSIS RAIL' JUST BEHIND THE GEARBOX SUBFRAME . NOT SUPPORTING THE GEARBOX SUBFRAME!
Try to push the van over.
Remove the front wheels
Disconnect the battery
Unclip the exhaust rubber bungs and move to as out of the way as possible.
Remove exhaust Heat shield.
'Score" the Prop shaft to Gearbox & prop shaft to rear Diff alignments with a Grinder or similar.
Remove the prop shaft.
Drain the clutch into a suitable container. Release Clutch pipe clip & tuck the pipe away from the gearbox.
Remove gearbox ancillaries. 2 tiny wires at the very rear. A difficult 'blind' clip electrical connection under the drivers floor.
Gear selection cables seem to simply push out with force. The Gearbox cable brackets. Pull on the serrated plastic cylinder to remove from the bracket.
Remove starter motor & tuck out of the way ideally all still connected.
Undo Gearbox bolts . Some very tricky ones under the drivers floor be patient & maybe just go & get the socket extentions & u/js.
Undo the 2 gearbox to gearbox subframe bolts . Rear underneath.
Lever the gearbox back to check for separation. Really need to get the gearbox spigot shaft visually clear. Of the clutch splines.
2.......... Place trolley jack with rubber contact sheet. under & support the gearbox subframe
Undo & remove the 4 nuts & bolts connecting the Gearbox subframe to the Vehicle body. The front 2 bolts require a 21mm Deep Reach impact
socket.
Slowly lower the trolley jack & check for a 'Free' gearbox. Adjust as required attempt if required. The gearbox should lower with the subfame
& not DROP !! onto the power steering lines.
BE AWARE THAT AT THIS MOMENT IT SHOULD BECOME A FREELY MOVING HEAVY GEARBOX AND IT'S UP TO YOU TO DECIDE IF YOU WANT A MORE
SUBSTANTIAL 'CATCH/HOLD/LOWER ' SAFETY EQUIPMENT OR IF YOU WANT TO PULL IT BACK TO CARRY OUT CLUTCH/FLYWHEEL & BELL
HOUSING WORK. I WAS AMING FOR THE LATTER AND JUST HAD THE WHOLE LOT HANGING/WEDGED !
ONCE THE GEARBOX SUB FRAME IS FULLY DISCONNECTED THE TROLLEY JACK CAN BE REMOVED OUT OF THE WAY!
THE WHOLE ASSEMBLY JUST HANGS ON THE FRONT SHOCKS !! HOW IT'S DESIGNED !
HOPE THIS HELPS !!! AND DON'T FORGET TO DO UP YOUR NUTS !!!
