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Changing Gearbox Problem

#1 User is offline   pumapet 

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Posted 06 January 2012 - 07:59 PM

Hi, I'm changing the gearbox on a 1.7, but one of the circular cogs that fit over the driveshaft where it goes into the gearbox (is that part of the diff?) has slipped out of place, and I cant move it back.
Do I have to dimantle the gearbox to fix it, or can it be done by taking out the oil seal and the bearing underneath it? I be grateful for any advice. Peter


#2 User is offline   ScubaSteve 

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Posted 06 January 2012 - 08:55 PM

No you should be able to push it back into place as is, are both wheels off the ground?

You wont be able to access the bearing via the oil seal, when you remove the seal you will have a metal flange part of the casing that sits between the bearing and seal, only way to access that is to take box apart

you want to avoid taking the box apart as that will require a ford special tool to remove 5th gear

This post has been edited by ScubaSteve: 06 January 2012 - 08:57 PM


#3 User is offline   CartMan 

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Posted 06 January 2012 - 09:27 PM

not to disagree, but I'we removed the 5th gear many a time with just a normal hmmm, what's the english word, puller?? like this :) Posted Image

although this might be better :)

Posted Image
1998 Puma 1.7 Replica FRP. innlet nr 138
Projekt tread http://www.pumapeopl...pic=104790&st=0

Time, is the fire in which we burn

#4 User is offline   ScubaSteve 

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Posted 07 January 2012 - 08:39 AM

5th gear off an ib5 box? impossible unless the gear is already loose, eg knackered.

There is no room under the gear to fit a standard puller and by default they are very very tight

take a look at my pic with the ford tool in place

Posted Image

it doesnt highlight it very well but the gap between 5th gear and casing is a mm or so if that

#5 User is offline   CartMan 

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Posted 07 January 2012 - 08:45 AM

I didn't say it was easy :) lol, but before, when I didn't know there was a special tool, that is what I had to use, and it worked fine :) I'we rebuildt several ib5's that way, :) given, it's not ideal :) and I did use a werry verry smal puller in order to get it under the gear :)
1998 Puma 1.7 Replica FRP. innlet nr 138
Projekt tread http://www.pumapeopl...pic=104790&st=0

Time, is the fire in which we burn

#6 User is offline   volcomstone411 

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Posted 07 January 2012 - 09:00 AM

yea i had to use a 2 prong one to do it. And still modify it. I used a beta one.
Posted Image
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#7 User is offline   ScubaSteve 

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Posted 07 January 2012 - 09:35 AM

do you have any pics of what you used? im quite reluctant to believe any sort of gear puller trying to use conventional methods eg pulling from under neath the gear will work lol

if you modify it so the feet actually clear underneath then that will leave such small amounts of metal it will just bend the feet or snap

for the record i own a variety of 3 legged pullers and 2 prong ones and none of them even come close lol

This post has been edited by ScubaSteve: 07 January 2012 - 09:41 AM


#8 User is offline   CartMan 

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Posted 07 January 2012 - 09:58 AM

sadly no. it's been atleast 5 years since the last one, and I don't worke there anymore :( first time I did it was on my first puma back in 04 :)

what I can say is that I did bend it in the proses :)I think it was about 2mm thick, and 10mm wide. and it was a pain, when in need, you use the tools awailable :) right :)


I belive I loosend the gearhousing and vedged it slightly, to force it slightly up before, and then place the puller afterwards. :D
1998 Puma 1.7 Replica FRP. innlet nr 138
Projekt tread http://www.pumapeopl...pic=104790&st=0

Time, is the fire in which we burn

#9 User is offline   Ian G 

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Posted 09 January 2012 - 01:22 AM

So in summary it can be done but the proper tool is somewhat more desirable :roflmao:

#10 User is offline   CartMan 

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Posted 09 January 2012 - 05:02 PM

indeed :)
1998 Puma 1.7 Replica FRP. innlet nr 138
Projekt tread http://www.pumapeopl...pic=104790&st=0

Time, is the fire in which we burn

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