[NZT5]

Photo for those of you living in the Northern Hemisphere, not down under!

 

[NZT5]

Thanks Simon for reply, yes I checked brake fluid level, it was full, also checked for leak around clutch pedal. Now that I've got the starter off I also don't see any leak around slave cylinder, as I think I'd see some fluid stain on the DMF ?
The last bolt I did find was hiding above another bolt, by the differential, but as you say going from engine to gearbox.
Can you confirm I need to drop the whole subframe? Was hoping to avoid that,

 

[NZT5]

I have put this job to one side, waiting to see if anyone knows of a hidden Allen bolt or something that retains the drive shaft on the differential, most drive shafts have a ring of bolts or Allen bolts retaining them. Tomorrow , unless someone can suggest otherwise I'll put some serious force on that cv to try and pill it off.......bed time here in NZ

 

[NZT5]

Hi Dan, thanks for your reply, the cv drive shaft is ok, in frustration I undid one end of the boot and then released the drive shaft by releasing the circlip, that held the shaft into the cv. Today I had success, it just needed a lot of force, which was surprising as there was plenty of grease....... Then undid the Allen bolt and got the stub shaft out of the gearbox.

However I'm still in battle with splitting the gearbox from the engine, I've now dropped the sub frame, whilst I've got a little movement all around the clutch housing, so far it won't budge any further, I'm going to invest in some better pry bars and try again. I did have a chain attached to the gearbox, which I was then ratcheting against the shed wall, but the van was rocking on the axle stands so badly thought it wise to pack up.
I've looked for that LAST bolt holding it all together........but I cannot see it, I'm going to get a mate to cast his eyes over it. Anybody know what the plastic bung at the top of the clutch plate housing is for, it opens a hole about half inch, mines just full of clutch dust?

 

[NZT5]

Thanks Simon, new day here, yup I'm beginning to think there must still be a bolt at the top somewhere....... Using a trolley jack and a heavy duty motorbike jack + a couple of bottle jacks. When I get in there I'll be replacing the DMF, CLUTCH, CRB, and slave cylinder - this is a job I don't want to do again.

 

[NZT5]

Thanks Simon, your comments are a great help, I've put this to one side over last couple of days, the day job kept me busy
Weather is great here, one of the driest parts of New Zealand, but bit hot working on van, yesterday it got to 32C, the vans is a tin shed.....hanger.
Done a few minor things like put the shaft held by Allen bolt back in diff, clean k&n filter, buy some more pri bars , and search again for that last bolt holding it all together.........but I now think I have got them all

 

[NZT5]

Thanks Simon, no silly questions....all helpfull. I tried again no luck, it appears the gearbox is being held at the diff end, do you think on the 4motion the rear prop shaft needs removing to get the shaft free from differential?
I can't think of any bracket that's holding the gearbox, except the one that goes to the subframe - removed. Photo's below

 

[NZT5]

Thanks for continued support on this, definitely have removed bolt in starter casing, I can now get about 1/4 inch movement on that side of the gearbox, think all bolts are removed, including the ones close to another. It does't appear to be releasing around the diff.

3 bolts removed from sub frame, last one is loose, it's dropped about 4 inches on gearbox end, ie there is plenty of room to get off the engine, well at least start to get it off, if I need more I'll continue to lower, but at the moment didn't want to stretch any hoses or wires attached to engine. .......although the way it's going maybe I should just undo everything and drop the lot on the ground?
Had to reattached far engine mount so that I had something to pull against, whilst using the chain.
Tomorrow's another day, temp got up to 36c today, we're expecting same tomorrow.

 

[NZT5]

FOR SALE T5 4MOTION AS IS WHERE IS

another day crawling around under van, photo's show progress..... Minimal but we're getting the gearbox off, BUT the diff is refusing to part from gearbox. I'm presently trying to undoe the pinion bolt on the output to rear prop shaft..... Of course everything just turns, probably meant to undoe with wheels on ground and drive shafts fitted!!!! Put some bolts in and wedged a bar between them, but that pinion bolt is real tight.
Looks like the diff is coming out too, which of course makes it heavier and requires more of a gap!!!!

 

[NZT5]

THE CLUTCH IS OUT and it's fooked

The gearbox isn't out, as I couldn't get the diff of it, so I ended up just working with the gap between the engine and bell housing. Haven't got the DMF off as I had to go to town to get another type of mult- headed (splined) socket, but it appears to have about half an inch of radial movement, so I guess it's fooked too. Ordered the parts, looks like a week away - have to come from Austrailia - nothing new there.

 

[NZT5]

New DMF clutch and slave cylinder/ release bearing fitted. Wasn't a smooth ride, first time I put the DMF in last of the 8 bolts wouldn't line up.........yes there is only one position that it fits.....mark the position of the old one! And another question that I'm not sure I want to know the answer to which way round does the clutch plate go, I fitted mine bulging side out ( towards gearbox), once again I didn't remember how mine came out, mine did just fall out in pieces- but I should have noted which way round.:*

 

[NZT5]

All back together and working a treat, biggest hassle was waiting for the diff oil to seep in to the filler, BE WARNED ( I thought it was worth changing diff oil whilst I had van in bits) The diff drain and filler are Allen bolts, so I thought it would be easy, however the filler has only got a small slot behind bolt, which makes filling very difficult, and slow, I had to use a very small diameter pipe which means it took hours to fill, T:be warned.