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Magnus K · Posted: Wed Nov 17, 2004 7:21 am Post subject: Can't get the gearbox out...

Hi!

Me and a friend spent most of this evening trying to remove the 4 speed gearbox from my 924. The thing just won't come off...

All seems to be loos except the connection piece between the transmission axel and the axel that goes inside the gearbox. The only thing that happened here is that it seems like the axel in the trans-tube came out about 10 mm (or 1/2 inch), nothing more.

I loosened the Allen screw on the connecting piece, just the one closest to the engine since I can't reach the rear one...

You guys always seems to have some good advice, please share the secret of gearbox removal with me?

/Magnus
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CMXXXI · Joined: 05 Nov 2002 Posts: 1939 Location: Vicksburg, MS

If it is like the 931, you have to take that allen-head bolt completely out. Both the shaft running the length of the torque tube, and the shaft that goes into the transmission have a "notch" in them (across the shaft) where the pinch bolt goes. On reassembly you have to make sure you align things right or you can't get the pinch bolt to go all the way through.
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Magnus K · Posted: Wed Nov 17, 2004 7:39 am Post subject:

924guy · Posted: Wed Nov 17, 2004 10:21 pm Post subject:

i remember puzzling over the same problem..felt a little silly afterwards when i figured out all i had to do was take out that little bolt... I think the engineer that designed it that way had a sense of humor, and probably still chuckles when he thinks about it.. i know he got me...

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Eric
78 924
82 931 SE "smokey"
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My924gtc · Joined: 14 Aug 2004 Posts: 1362 Location: 248

Been there done that first time I pulled a gearbox. It sure came out easily after all that.
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MJ
'81 924 2.0L T
'82 924 2.3L SC/EFI <---online fall '06

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5150 · Posted: Thu Nov 18, 2004 1:24 am Post subject:

Sorry, each time I've looked at the title I've just wanted to suggest waving a dress and a wig at him... perhaps a nice pair of high heels too.. ooh and a matching handbag

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-nick · Joined: 16 Nov 2002 Posts: 2699 Location: Cambridge, MA

I think we've all been had by this

This should really be at the top of any clutch change how-to and in bold letters.

ps- make sure you position the torque tube shaft back to spec (per the haynes). You've probably pulled the shaft out a bit by wriggling the tranny (use a rubber mallet to tap it back in to the right measurement).

5150- what kind of places do you hang out at?

nick

Eturbo924 · Joined: 09 Nov 2002 Posts: 2212 Location: Londonderry NH

Ok just taking the bolts out some times is also not enough.

Have done this three times. Once taking the bolts out was enough.

If the fails you need to get a nice strong screw driver or crow bar. Put the flat edge in the channel in the coupler and pry it open a bit. Then the coupler will slide real easy right onto the transmission and the transmission should then of course come right out.

Eric

www.geocities.com/eturbo924
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Joes924Racer · Posted: Thu Nov 18, 2004 3:20 pm Post subject:

Be careful too. I had to get in there once caue I busted my coupler maged to put it all back together though with a new coupler... it was a couple years ago.. man did it vibrate with a busted coupler.

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Magnus K · Posted: Thu Nov 18, 2004 8:56 pm Post subject:

5150 - OK, so I changed the subject so that you won't have any nasty ideas no more.

Nick - Yeah, the shaft is probably 6-7 mm too far out. I'll try to remember to get it in place before reassembly.

Joe924 - I did bust the coupler...

The squeezing clamp closest to the engine came loose from the coupler, the weld spot just gave away... was that part expensive? Is it possible to weld the clamp back on the coupler without getting those bad vibrations?

Anyway, yesterday I got the gearbox out of the car. The problem was the coupler and those evil little hex bolts. It was a bit scary, though, all alone under the car and trying to get the gearbox down with only a large hydraulic jack...

The gearbox seems like it's OK but it's obviously leaking somewhere but I'll explain that in another subject. The other subject: Leaking transmission

Thanks for all the help!

Magnus
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Asleep in Sweden, Europe, when you US guys are awake...

Smoothie · Posted: Thu Nov 18, 2004 11:11 pm Post subject:

Eturbo924 · Joined: 09 Nov 2002 Posts: 2212 Location: Londonderry NH

My first coupler also came apart at the weld. I had it repaired (welded) never had any vibrations from it.

When ever I am under the car I always have at least two jack stands under the car with me. One holding the car... one for a back up. Plus normally I will also have the jack also holding it. Since it has wheels it will move with the car... if it were move. As a final back up if I have the wheels off... I put them under and area of the car that would catch it in the final event that some thing like an earth quake happened.

My wife appreciates it....

I might have an extra coupler around but I will have to check. It might be from the 944.

Eric
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1982 924
1992 968
2003 C4S
Parts Parts Parts and More parts.
E-mail me for parts you need!
Drive Fast!

rat · Posted: Thu Nov 18, 2004 11:37 pm Post subject:

i got the impression he meant on the jack to help him lower teh gearbox down instead of having it land on his head

924guy · Posted: Thu Nov 18, 2004 11:44 pm Post subject:

yep, thats how i did it...solo, jackstands, and a hydrolic jack to lower it down, gets a bit wobbly... the hard part is geting it back in.. you really need someone else to help get it lined up correctly..i spent two days trying toget that sucker back in, until i recruited my nephew to help me get it lined up..once i had help, it only took a few minutes to pop it in and get it bolted up...
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Eric
78 924
82 931 SE "smokey"
99' VehiCross
Y2K Honda Insight
http://www.cardomain.com/id/924Guy
Performance by Pasha

My924gtc · Joined: 14 Aug 2004 Posts: 1362 Location: 248

I agree...I think he meant using the jack to lower the gearbox. Balancing it on a jack is a bit nerve racking to do alone.
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MJ
'81 924 2.0L T
'82 924 2.3L SC/EFI <---online fall '06

Sponsor of the 944 Cup and Super Cup
Sponsor of the "2006 Battle in the Badlands"