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Discussion Starter #1
Happy new year all:) I have decided my new years resolution can be to try make my car as smooth as possible so first thing is to sort out the gearbox, my problem is when accelerating 3rd gear is a no go as it pops out when put in. Any ideas what the problem is? Gear synchro? Any idea on cost of a rebuild? And what kind of labour and difficulty is involved in removing and refitting the gearbox? And finally are there any special tools needed for the job? Thanks in advance:)
 

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Rebuilding the gearbox is a pretty specialist job, requiring gear pullers etc.

Much easier, and cheaper, to fit a replacement gearbox... Removing and refitting them isn't too bad. It can be done without dropping the front subframe, but it's easier if you do!
 

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Thats what I thought the case would be! Any idea on labour times if I can find myself a replacement from a breakers etc? And are there any gaskets or other parts I need for it? Thank you again:)

Oh and what sort of price should I pay a breakers for a gearbox? And is it only the 1.6 box I can fit? I say this as I have a 2.0 I bought last year for spares:) or would the different ratios have a negative effect on performance and mpg? And as it has not been driven in 1-2 years is this a problem? Thanks:)
 

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Thats what I thought the case would be! Any idea on labour times if I can find myself a replacement from a breakers etc? And are there any gaskets or other parts I need for it? Thank you again:)

Oh and what sort of price should I pay a breakers for a gearbox? And is it only the 1.6 box I can fit? I say this as I have a 2.0 I bought last year for spares:) or would the different ratios have a negative effect on performance and mpg? And as it has not been driven in 1-2 years is this a problem? Thanks:)
I guess it would take someone who was used to doing them 3-4 hours. To DIY, probably twice that (including tea breaks!).

Gaskets...no...none that I can think of. The end plate uses liquid gasket to seal, so if you take that off (eg to clear any swarf which can build up), have a tube handy. Replacing the diff oil seals might be an idea, but not essential.

Price... The ones I've removed from cars I've sold for about £75. The ratios are different in a 1.6 box, but a 1.8/2.0 one will fit. They're geared a little bit longer, so you'd get better MPG (in theory) but poorer acceleration. Of the two, the 1.8 uses the same clutch as the 1.6, so that's probably the better second option if you can't find a 1.6 box.

Obviously change the clutch and slave cylinder (which incorporates the release bearing) at the same time. The 6 nylock nuts on each CV joint should be renewed. The bolts should as well, to do it by the book, but I think that's just because they have thread lock pre-applied...
 

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Discussion Starter #5
I guess it would take someone who was used to doing them 3-4 hours. To DIY, probably twice that (including tea breaks!).

Gaskets...no...none that I can think of. The end plate uses liquid gasket to seal, so if you take that off (eg to clear any swarf which can build up), have a tube handy. Replacing the diff oil seals might be an idea, but not essential.

Price... The ones I've removed from cars I've sold for about £75. The ratios are different in a 1.6 box, but a 1.8/2.0 one will fit. They're geared a little bit longer, so you'd get better MPG (in theory) but poorer acceleration. Of the two, the 1.8 uses the same clutch as the 1.6, so that's probably the better second option if you can't find a 1.6 box.

Obviously change the clutch and slave cylinder (which incorporates the release bearing) at the same time. The 6 nylock nuts on each CV joint should be renewed. The bolts should as well, to do it by the book, but I think that's just because they have thread lock pre-applied...
Thanks for all the info, I better get searching! I think the box in my spares car is actually a 1.8 as originaly the car was a 1.8:) so I will check that! Regarding the clutch is there a preferred clutch kit? And regarding cost what should I be paying for these? Thank you again:)
 

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Discussion Starter #7
Cool thanks for the link, tomorrow I will make some calls to all the UK and Ireland suppliers I can find and will post back up on this thread the cheapest kit I can find for anyone that is interested! Thank you again it's really appreciated:)
 
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