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2005 Ka Gearbox Removal


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#1 durango

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Posted 18 May 2013 - 12:24 PM

Hi, I'm intending to replace the release bearing assembly. Can the gearbox be removed without uncoupling the exhaust? The Haynes manual is unclear as to which coupling on the exhaust needs unfastening. There are two heat-shields situated above the RH driveshaft, the upper one has rusted bolts. Can the engine be canted down without having to uncouple the exhaust pipe? The car is on axle stands.



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#2 Steelie600

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Posted 18 May 2013 - 01:51 PM

you can swing the KA box on the shafts.

 

Undo the gearbox mountings, bell housing bolts and gear linkages and anything else connected to the box. then wiggle the box off the clutch (may need a lever bar) and then swing the box down on the shafts.

 

Personally if your doing the release bearing id do the clutch aswell. While your in there etc



#3 durango

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Posted 18 May 2013 - 03:35 PM

you can swing the KA box on the shafts.

 

Undo the gearbox mountings, bell housing bolts and gear linkages and anything else connected to the box. then wiggle the box off the clutch (may need a lever bar) and then swing the box down on the shafts.

 

Personally if your doing the release bearing id do the clutch as well. While your in there etc

 

Thanks, I will proceed on that, if I don't have to touch the exhaust that will be great. Does the starter remain in situ?

 

It's actually a pronounced whirring noise which disappears when the pedal is depressed. The car has only done 14k, I think the previous owner must have rested their foot on  the clutch pedal.



#4 wase16ll

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Posted 18 May 2013 - 07:59 PM

starter has to come off.

you also might make your life a little easier if you disconnect the drivers lower ball joint, gives  a bit of movement to allow box to pull away from the engine a bit easier and much easier to put the box back too



#5 Steelie600

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Posted 18 May 2013 - 08:08 PM

Agree with above

 

Starter does indeed need to be moved back out of the way MAKE SURE you disconnect the battery first!!

 

And yeah popping the ball joint will give a bit more room but you can do it without



#6 durango

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Posted 18 May 2013 - 08:13 PM

starter has to come off.

you also might make your life a little easier if you disconnect the drivers lower ball joint, gives  a bit of movement to allow box to pull away from the engine a bit easier and much easier to put the box back too

Thanks, first job tomorrow morning. 

 

Just one further point, does the entire RH engine mount have to be removed as per the manual?



#7 Steelie600

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Posted 18 May 2013 - 09:01 PM

not as i can recall, I take it you mean the one that goes back of diff to subframe?



#8 durango

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Posted 18 May 2013 - 09:12 PM

Manual just says "unscrew single bolt and two nuts then remove engine mounting upper bracket" then lower the engine.

 

Thing is the design is so compact its not obvious to the uninitiated whats going off!



#9 durango

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Posted 19 May 2013 - 05:49 PM

Hi, do I expect to lose all the gearbox oil as I undo the bolts? There's 8 on the lower end of it, 2 at the top and another 2 on top of bell housing.

 

Unexpected problem- the power steering pipes appear to be obstructing the LH gearbox mount when it comes to be lowered, see pic.

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