Help changing turbo gearbox

taza · Post by **taza** » Sun Dec 09, 2012 8:36 pm

Guys well I am helping Adrian change the geaarbox in his Forester GT after the centre diff shat itself..
Now we have disconnected everything but can't the the gearbox off the back of the motor... It's about half way off, got stuck then we realised you need to take the pin out the side for the clutch fork.
The problem is we can't get the pin out now or get the gearbox to move completely onto the motor, it's all just jammed and we don't really know what to do...
Is it likely we have bent the pin or what?
Any tips to help get it out and get the gearbox off...?

Thx

taza · Post by **taza** » Sun Dec 09, 2012 10:39 pm

bump, really want to get this fixed asap

niterida · Post by **niterida** » Sun Dec 09, 2012 11:19 pm

Try asking on rslibertyclub

LLOUD · Post by **LLOUD** » Mon Dec 10, 2012 7:20 am

Did you pull the clutch fork pin out? If no, you will a 10mm allen key to pull the plug on the lh side of the box just below the starter. After that is out remove the pin by putting a M6 bolt in the centre of it. once it is out lift the clutch fork out of the throw out bearing.

taza · Post by **taza** » Mon Dec 10, 2012 9:21 am

That's the pin I'm talking about. We cant get it out, I've taken the.cap off and put a 6mm bolt in but even with multi grips we cant get it out. Nor can we get the.box.tiff mate back with the motor, it's kinda stuck half off, half on...

LLOUD · Post by **LLOUD** » Mon Dec 10, 2012 4:36 pm

I usually put a bolt in long enough I can put a pry bar behind it. Failing that if you get the gearbox out far enough the is a ring on the pressure plate between it and the throw out bearing that you need to jam a scewdriver either side to release the bearing.

d_generate · Post by **d_generate** » Mon Dec 10, 2012 8:53 pm

Why didn't you take the rear housing off and swap the center diff over, no need for box to come out, sometimes if those pins get dry they can rust a little and get stuck......long bolt and beat the shit out of it by making something like a slide, maybe long pair of pliers over the bolt shaft and smack it hard.

taza · Post by **taza** » Mon Dec 10, 2012 10:08 pm

Got the pin out

With a big 1m pry bar and hammer, came out straight an unbent. Only took a few mins, was getting frustrated by the end of yesterday.....

Got the box off too, by myself. Now that was hard with just one person but I did it

When putting the new box on do I need to put this(thrust bearing is it??) on the gearbox spline an fit the clutch fork before putting the new box on?

LLOUD · Post by **LLOUD** » Tue Dec 11, 2012 5:55 am

Yes you do. you need to assemble it back with the pin and fork. clean the pin and gearbox snout and get some good anti seize.
See those thin metal rings between the throw out bearing and the clutch pressure plate? Push them pack towards the pressure plate then pull the bearing out.

guyph_01 · Post by **guyph_01** » Tue Dec 11, 2012 7:25 am

Be careful when removing the thrust bearing or you might **** it up. there a little pin like was explained above. Put the pin back on the new gearbox and the thrust bearing on the pin. Once the motor and box are together, you can ingage the trust bearing by pushing the fork lever by hand and you will feel it go in. Also you will know thats its in as you won't be able to push the clutch in by hand.

Enjoy:)

woody.t · Post by **woody.t** » Tue Dec 11, 2012 7:20 pm

hey dude, on a side note... the old box does it happen have that tube that screws into the box and the speedo cable plugs into the top...? i am in dyer need of one.. chuck me a message on 0430955187 if so

LLOUD · Post by **LLOUD** » Tue Dec 11, 2012 8:40 pm

Or Can I have the old box?