Taking out g'box on GT5S....

knobstar · 25-01-08, 09:14 AM

....is a right f*cking pain in the ar$e!!!! 15 hours spent trying so far and I'm still not there! (Most of which has been spent trying to hack and chisel-drive bolts on the driveshaft flange bolts admittedly, but still...)

Spent an hour or so last night with a mate holding the engine while I pulled on the 'box as hard as I could from underneath and nothing...
The 'box is supported on the jack and the engine by blocks so no weight (hopefully ) is being transferred to the input shaft. I've undone and taken out a total of 9 bolts: 4 that I accessed by lying on the engine and reaching down; two (13mm) bolts that are screwed in vertically to the block from the gearbox 'support finger' on the n/s; 1 from the gearbox support bar that pivots about one of the subframe bolts on the n/s; two from the o/s that hold the starter motor in. Over-engineering or WHAT!??!? Whilst I realise a beetle's engine is lighter than a straight-5; a beetle's engine is ENTIRELY supported by four bolts - this has two ruddy great big engine mounts ffs! Mini rant over.
Anyway, the bits that iare confusing me are 1) the three remaining bolts at the bottom of the bellhousing that, as far as I can tell, are connect the aforementioned ' support finger' to the box - are my perceptions right? 2) the one bolt on the n/s, accessed from above, that isn't able to pull out fully because of the clutch arm - could it be binding?

ANy help would be most gratefully received

Cheers,

Matt

Puglife · 25-01-08, 09:49 AM

Not worked on a GT5s but can only assume its similar to a quattro coupe without a propshaft out-take..... you need a special star allen key to undo driveshaft bolts.... cutting heads off makes it very hard....
once all bellhousing bolts are off and starter motor removed, check the flywheel cover plate isn't still bolted in by i think its 3 small 13mm head bolts? (iirc).
You may have to undo bottom balljoints off the hub/wishbone to move driveshafts away from gearbox....
Get jack under the centre of gearbox and under two mounts then try with a big rubber mallet tapping bellhousing free of block... Make sure gearbox isn't in gear and flywheel and clutch can clear any intrusions to bellhousing (don't think you'll have flywheel sensors etc).

knobstar · 25-01-08, 12:01 PM

You saying I have to undo the three bolts at the very bottom of the bellhousing? I can't begin to imagine how to get at them as the subframe is totally in the way! I just thought they were attaching the alloy support finger (that bolts with two 13mm bolts vertically to a horizontal flange on the block) to the gearbox and was nothing to do with the engine belllhousing....?

Puglife · 25-01-08, 12:05 PM

not sure quite what you mean but there is a cover plate that goes over the flywheel and is bolted to the gearbox iirc... jacking engine up should give space above subframe to undo them.

pimpdriver · 25-01-08, 12:16 PM

Take it to Audi-Volks in Keynsham. A very nice man will do it for ya!

He had to chisel off all 12 driveshaft bolts.

Baggee · 25-01-08, 02:14 PM

What does Mr Haynes Manual say. He always makes it lok and sound very easy. Keep pluggin away and Good luck

randall977 · 25-01-08, 02:18 PM

Is the bit you mean in this diagram?

Audi-Gbox-Manual017.jpg

I have the workshop manual for the 016 5spd gearbox - which I think is yours (or very simular!). It was available through the link under the 'useful technical resource' section of this website but I couldn't find it when I looked. I can try and email it to you if you want?

knobstar · 25-01-08, 02:59 PM

Which bit? I can't see it labelled on diagram

Oh well; will jack engine up to get at final 3 bolts to remove any suspicion. ALso will take off the steering tie-rod to make doubly sure that nothing binds...

Tonight's the night!

Puglife · 25-01-08, 08:01 PM

Quote:

Originally Posted by randall977

I have the workshop manual for the 016 5spd gearbox - which I think is yours (or very simular!). It was available through the link under the 'useful technical resource' section of this website but I couldn't find it when I looked. I can try and email it to you if you want?

016 is the URquattro gearbox.
if all bellhousing to block bolts are out and the starter motor is removed i don't see why it wont free itself. have you tried using a pry bar and some old rags so as no to damge the faces of bellhousing etc...

knobstar · 25-01-08, 08:59 PM

Can't get to those bottom three bolts without without removing subframe - so am assuming that they're just bolted to the gearbox save the two vertical; bolts. Have drawn a (particularl;y shite) sketch in paint to try and roughly indicate the shape of this alloy bracket with a finger on it! Imagine looking from the engine side of things when looking at it...

You, or anyone else, ever seen one of these?Differtent material to gearbox but blatently not cast iron like block so very easy to distinguish one from the other...just getting the gearboxoff still remains the issue

25-01-08, 09:49 AM	#2
Puglife ==>PUGSPORT!<== Classic Audi Club Member Join Date: Jan 2008 Location: Leyland Posts: 1,544	Not worked on a GT5s but can only assume its similar to a quattro coupe without a propshaft out-take..... you need a special star allen key to undo driveshaft bolts.... cutting heads off makes it very hard.... once all bellhousing bolts are off and starter motor removed, check the flywheel cover plate isn't still bolted in by i think its 3 small 13mm head bolts? (iirc). You may have to undo bottom balljoints off the hub/wishbone to move driveshafts away from gearbox.... Get jack under the centre of gearbox and under two mounts then try with a big rubber mallet tapping bellhousing free of block... Make sure gearbox isn't in gear and flywheel and clutch can clear any intrusions to bellhousing (don't think you'll have flywheel sensors etc). __________________ 1986 UR Quattro - (1982) Lombard RAC Group 4 recreation - #24 H.Demuth/J.Daniels 1981 VW mk1 golf GTi - now 5cylinder and RWD.

25-01-08, 12:05 PM	#4
Puglife ==>PUGSPORT!<== Classic Audi Club Member Join Date: Jan 2008 Location: Leyland Posts: 1,544	not sure quite what you mean but there is a cover plate that goes over the flywheel and is bolted to the gearbox iirc... jacking engine up should give space above subframe to undo them. __________________ 1986 UR Quattro - (1982) Lombard RAC Group 4 recreation - #24 H.Demuth/J.Daniels 1981 VW mk1 golf GTi - now 5cylinder and RWD.

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25-01-08, 12:01 PM	#3
knobstar Grown up member Classic Audi Club Member Join Date: Sep 2007 Posts: 253	You saying I have to undo the three bolts at the very bottom of the bellhousing? I can't begin to imagine how to get at them as the subframe is totally in the way! I just thought they were attaching the alloy support finger (that bolts with two 13mm bolts vertically to a horizontal flange on the block) to the gearbox and was nothing to do with the engine belllhousing....?

25-01-08, 12:16 PM	#5
pimpdriver Devon Pastie Muncher Classic Audi Club Member Join Date: Jul 2007 Location: Calne Wiltshire Posts: 7,530	Take it to Audi-Volks in Keynsham. A very nice man will do it for ya! He had to chisel off all 12 driveshaft bolts.

25-01-08, 02:14 PM	#6
Baggee 4 ring whore! Classic Audi Club Member Join Date: Nov 2007 Location: Aldridge, Walsall Posts: 2,257	What does Mr Haynes Manual say. He always makes it lok and sound very easy. Keep pluggin away and Good luck

25-01-08, 02:18 PM	#7
randall977 Mr Typ 43! Classic Audi Club Member Join Date: Sep 2007 Location: Oxfordshire Posts: 838	Is the bit you mean in this diagram? Audi-Gbox-Manual017.jpg I have the workshop manual for the 016 5spd gearbox - which I think is yours (or very simular!). It was available through the link under the 'useful technical resource' section of this website but I couldn't find it when I looked. I can try and email it to you if you want?

25-01-08, 02:59 PM	#8
knobstar Grown up member Classic Audi Club Member Join Date: Sep 2007 Posts: 253	Which bit? I can't see it labelled on diagram Oh well; will jack engine up to get at final 3 bolts to remove any suspicion. ALso will take off the steering tie-rod to make doubly sure that nothing binds... Tonight's the night!

25-01-08, 08:59 PM	#10
knobstar Grown up member Classic Audi Club Member Join Date: Sep 2007 Posts: 253	Can't get to those bottom three bolts without without removing subframe - so am assuming that they're just bolted to the gearbox save the two vertical; bolts. Have drawn a (particularl;y shite) sketch in paint to try and roughly indicate the shape of this alloy bracket with a finger on it! Imagine looking from the engine side of things when looking at it... You, or anyone else, ever seen one of these?Differtent material to gearbox but blatently not cast iron like block so very easy to distinguish one from the other...just getting the gearboxoff still remains the issue