5 Mk I incl Gordini Is it me or is the Mk 1 R5 Haynes manual a bit... crap? Can’t get my gearbox out!

[Simon69]

Hi, obviously isolation men’s I’m getting round to loads of jobs. The first is to drop the gearbox out of the r5 and set to work in tidying up the engine bay. It looks like it’s Ben repeatedly dipped in salt water as it’s fine from the a-pillars back.
i have taken out so many bolts and I’m certain I’ve got them all but I can’t separate the ‘box from the engine. What am I missing? Is there a trick to this?

 

[Adey]

I'm sure it was easier to pull the engine and box out last time I did it. cant help on what you may have forgotten though sorry

 

[ren5gord]

Yes, alot easier to take the engine and gearbox out. The bell housing and starter bolts are time consuming.

 

[gordini stu]

If you just what to take the gearbox out pm me and we can have a chat on the phone . Here’s a few thing s
Exhaust. To let the engine flex down .
Cross member out , it’s on slots so the bolts don’t have to come right out
Bottom starter bolt is fiddly
They do get stuck on the dowels
If you do take the lot out the rack has Shims to set its height they can be different side to side .

 

[Simon69]

So I think I'll also have to remove the steering rack to get the whole lot out? I guess that it will make reinstallataion much easier. I have the feeling that the engine mount at the back is toats. Are they easy to get hold of?

 

[Simon69]

'toats' = 'toast'.

 

[DaveL485]

I bet you missed the stud/nut on the back by the starter motor.

All the bolts around the bellhousing have to come out, then you gotta get underneath round by the starter motor, there's an M10 stud that sits in the box and goes through the engine casing with a 16mm nut on the back, on the opposite face to where you took the bellhousing bolts out.

 

[Simon69]

Got massively distracted by garden projects so I’m back on it. Removed the steering rack, removed about 20 studs (some unnecessarily I’m sure) and I can now wiggle the gearbox out by about 5mm. But it’s reaching a very solid stop point and I just cannot figure out what’s stopping it. I’m sure it’s just a stupid oversight. Can anyone think what it might be? I’ve followed all the above advice and I’d go the whole hog and take the engine out too but ibdont have a winch. It’s a 1227.

 

[Adey]

not left the selector on it or anything? maybe get a load of pictures up and we might see something

 

[Simon69]

 

[Simon69]

I don’t know if that shows anything helpful. It feels like there’s something done right with 5 mm of play in it. But ALL the studs are out. Is there anything inside/under the sump tray?

 

[Simon69]

Do I need a hoist? Is there anything stopping me dropping the engine and trans out the bottom?

 

[DaveL485]

Have you got the 16mm nut off the stud that sits around the back? The stud comes out of the 'box, through the block under the starter motor. Its the only one that points the other way if you see what I mean.

 

[ren5gord]

The engine and gearbox only come out the top you cant drop it out the bottom.

there is a long bolt that come through from the starter side as Dave said, that need removing.

 

[Adey]

have you taken the driveshafts off?

 

[Adey]

Looking back at the last time i did the job i pulled the whole lot out, engine and box and then fitted back separately. Not that that helps but here are some pics just in case it lets you see something new.

 

[Simon69]

Thanks. I didnt know I could remove the front cross member. I’ll have a poke about later, I’m sure you guys are right and I’ve just missed something.

 

[Turbell]

Did the clutch operate before you started?
Looks very rusty, been a while since I took a box out of a Mk 1, but could pressure plate be rusted on splines?
Cam passes through bell housing , I once bought an engine and they’d snapped cam off trying to rip it out...but I see you’ve got that off, so I’m thinking there’s something internally causing grief

 

[Simon69]

Did the clutch operate before you started?
Looks very rusty, been a while since I took a box out of a Mk 1, but could pressure plate be rusted on splines?
Cam passes through bell housing , I once bought an engine and they’d snapped cam off trying to rip it out...but I see you’ve got that off, so I’m thinking there’s something internally causing grief

You spotted that. That’s why I’m taking it out. It’s very rusty in there. The engine runs fine but I just couldn’t free the clutch.

 

[Turbell]

Everything else off, then that'd be my guess, perhaps clutch went in with no grease on splines however many years ago, don't know if you can give a smack with a piece if hardwood and a hammer through any gaps, or oink a tin of release spray in and keep side to side pulling it, just be careful putting in any pry bars.....engine will be wobbling about on mounts I imagine so any force you are putting in it will end up minimal on the actual seized bit.
If you're absolutely sure there's nothing physical stopping it coming off then that's my guess, spray and wobble, up down left and right....keep at it , and walk away and come back, don't get medieval on it, 'cos that's when things go wrong.....good luck!
If still it refuses then pull the lot out so dog can see rabbit, one bloke on motor and one on box should shift it.