Gotta split the box!

[Sparky]

Should be a fun one this weekend - ENORMOUS oil leak from an S4 gearbox.  No doubt I'll forget to take photos...

[Simon350S]

Have fun. Don't drop any important bits down the drain

[Sparky]

Boooiing

[Simon350S]

p.s. can I park a fire damaged esprit on your drive and pick it up in a week or two fixed and working, you know, as a favour.....

I so desperately want to bid on that eBay one!!!

[Sparky]

Get it here by lunchtime and it's a deal.

[Sparky]

Quelle surprise!  As usual, nothing went as planned and this box has thrown me a curve.

 

Everything went beautifully to plan and the box was out this morning.  Get the car high enough and it'll just slip out to the right.

 

 

Noticed something a little scary.  These 2 pics show the limits of in/out travel of the sleeve (clue: there should be none).

 

 

 

Nothing for it but to continue necessary steps for primary seal replacement. Don't forget the detent ball & spring!

 

 

Whoops - forgot to take a bunch of pics along the way, but Chris (internets) might add some...

 

 

Here comes the scary stuff.  This damage almost looks precision machined.

 

 

In a nutshell, the primary shaft roll pin, it seems, had sheared and migrated.  In so doing, it had completely severed the input shaft sleeve.  Here's the sleeve, compared to a good one, with what was left of the roll pin.

 

 

And here's a grape-sized bolus of swarf collected by the magnet.

 

 

There doesn't seem to be any other damage, and I can't find any more bits rattling around.  Looks like I get a day off tomorrow, awaiting parts...

 

 

 

 

 

 

[andydclements]

I don't know how you managed it today. I was preparing foe the cylinder head swap, I did a few mins then gave up because of the heat, have few mins in the shade/ sit down and repeat. Now that it's cool enough I have pulled the water pump pulley flange and realised I don't have gas for the torch to heat the casting, so nothing on that part until B&Q open at 10 am.

[Sparky]

Wasn't hot here mate.  Actually monsooned for about 30 mins - fortunately after the box was out.

 

Oh, forgot - drain plug buggered so things got a bit messy!

[Mysterae]

Nice one Gary, although I'm happy to have a go at most things, you guys removing gearboxes and splitting them open etc; next level up!

[Sparky]

Gotta be honest - first UN1 I've ever opened!  I normally get a specialist to do them but thought it was about time I bit the bullet.

[pete]

you should get Martin to set you up a live webcam

[Mysterae]

You sparked my interest in gearboxes (no pun intended) and found an interesting video on youtube.

 

http://youtu.be/vOo3TLgL0kM

 

The guy has an annoying cough but bearable.

[Vulcan Grey]

The UN1 is easy.

 

I did make one mistake though.  Moved all the shafts to extents, and the reverse ball and spring popped out...  I didn't notice and went to pop the shafts back to neutral, and the reverse shaft crushed the spring!

 

Had to replace that one.  Oops!

 

 

You should install a nice Quaife LSD while you are in there;)  Huge improvement in rear traction! Even more than the 285mm V8 tires!

 

 

Not that you would forget, but don't forget to check the differential preload via the drag spec when you put it back together.

 

 

https://picasaweb.google.com/116113253735518541549/LotusQuaifeLSD#

 

https://picasaweb.google.com/116113253735518541549/LotusClutchAndTranny

[Sparky]

We were talking about the LSD yesterday!  Would be sooooo easy right now.

 

Hoping the preload will be just peachy...

[Petrol feet driven]

I have full trust in you mate, sh**ing bricks but wow those images made me shake!

How much transmission oil was left?

[Sparky]

About enough to silence a noisy door hinge.

I did find about 2 litres though - most of it on my clothes at the end of the day. :-)

[Doulou]

Fancy doing another one pal?!!!!

[Sparky]

Uh-oh!  Wassup?  Missed your call so will try and get in touch tomorrow...

[internets]

Some of mine....better late than never!

 

 

 

 

 

 

 

 

[Vulcan Grey]

To split the box, you didn't have to take off 5th gear, just the 3 bolts in that plate.

[Sparky]

I know that now!  I was told to by someone highly knowledgeable, so I did.  I don't think leaving fifth on would have prevented me getting the main seal out...

[rogerch]

And you didn't take pictures of disconnecting the drive shafts ! I'm soooooooooo, disappointed.  

[Sparky]

I did!  They looked lovely on the big screen via my new Chromecast.