Broken Gearbox - Phase 5 New gearbox Install

Broken Gearbox - Phase 5 New gearbox Install

Next Phase 5 was to install the gearbox on Friday afternoon. Despite the rain showers the install went OK.

Major problem was the EMPI aftermarket front mount! There are just 4 holes. Two go on the gearbox and two mount to studs on the chassis from gearbox mount. Bolted to the gearbox was done in phase 4.Once the gearbox was mounted and the rear 27mm bolts installed but not torqued down. The two outer holes only one would line up enough to get the nut on!

Spent the next 3 hours attempting to adjust to get the 2nd nut on. G-Clamps, crowbars and lots a swearing did not make it want to fit.

Removed the mount and found it was curved so always one hole would never line it.

Another failed attempt led me to revert back to the stock Brazilian mount! Which of course fitted in 2 minutes!

The lesson is 

"Aftermarket parts never fit without modification, Stock parts quickly fit first time every time!"

I assume in a car factory assembly line time is critical and stock parts must be able to fit quickly first time.

So once the mount was secured in CV joints where fitted up but not torqued down. Most other items where installed such as Bowman Tube and Clutch cable etc.

Here is the finished install:

Rear EMPI Mounts & 27mm Bolts:

Left & Right Beetle Inner CV Joints:

Stock front mount (with additional new earth wire)

:

Front Linkage:

So finally stopped at 9pm on Friday night with everything installed.

Saturday morning started at around 11am. Torqued down 27mm rear bolts and front mounts. CV joints torqued down and boot clips installed.

Starter motor refitted & reverse light switch connected.

Saturday Lunch all finished ready for Phase 6 - Engine Install!