405 Gearbox Rebuild and Clutch Change
Moderator: RichardW
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- (Donor 2020)
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I'll see if I can get it whipped back out tonight. I'll double check everything, but what I might do is transplant the hub from the new shaft onto my original one. That will rule out any defect or differences, and it will eliminate the possibility of me getting the preload wrong.
Clutch feels great!
Clutch feels great!
'96 405 1.6 GLX with 306 GTI engine on Cat cams @ 195bhp
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
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OnlineCitroJim
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Jolly Good Ally...
Pleased you have a good, robust attitude to this
I'm going to study preload a bit. I have a gash BE3 here...
Where are you located? If you're not a million miles away from me or en-route to one of my frequently visited places, I might be able to cast an eye...
Pleased you have a good, robust attitude to this
I'm going to study preload a bit. I have a gash BE3 here...
Where are you located? If you're not a million miles away from me or en-route to one of my frequently visited places, I might be able to cast an eye...
Jim
Runner, cyclist, time triallist, duathlete, Citroen AX fan and the CCC Citroenian 'From A to Z' Columnist...
Runner, cyclist, time triallist, duathlete, Citroen AX fan and the CCC Citroenian 'From A to Z' Columnist...
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- (Donor 2020)
- Posts: 742
- Joined: 17 Apr 2008, 22:39
- Location: Clydebank, Near Glasgow.
- My Cars:
- x 2
Don't worry....it WILL get fixed The second time round should be a fraction of the time, everything's all clean and I know what I'm doing.
That's a very kind offer, but I'm near Glasgow, which I suspect is not very handy?
That's a very kind offer, but I'm near Glasgow, which I suspect is not very handy?
'96 405 1.6 GLX with 306 GTI engine on Cat cams @ 195bhp
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
-
OnlineCitroJim
- A very naughty boy
- Posts: 49532
- Joined: 30 Apr 2005, 23:33
- Location: Paggers
- My Cars: Bluebell the AX, Polly the C3 Picasso, Pix the Nissan Pixo, Propel the duathlon bike, TCR Pro the road bike and Fuji the TT bike...
- x 6163
- Contact:
I like your attitude a lot! Good on 'yer
No, it is quite a trek away I had a belief you were in Hertfordshire somewhere..evilally wrote:That's a very kind offer, but I'm near Glasgow, which I suspect is not very handy?
Jim
Runner, cyclist, time triallist, duathlete, Citroen AX fan and the CCC Citroenian 'From A to Z' Columnist...
Runner, cyclist, time triallist, duathlete, Citroen AX fan and the CCC Citroenian 'From A to Z' Columnist...
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- (Donor 2020)
- Posts: 742
- Joined: 17 Apr 2008, 22:39
- Location: Clydebank, Near Glasgow.
- My Cars:
- x 2
Too late, it's stripped down! I didn't notice it bent, but I'll double check that tomorrow! I've double checked the tooth count on all gears, they're idendical. So I think the plan will be to swap the hubs, tomorrow nights task.....
'96 405 1.6 GLX with 306 GTI engine on Cat cams @ 195bhp
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
-
- (Donor 2020)
- Posts: 742
- Joined: 17 Apr 2008, 22:39
- Location: Clydebank, Near Glasgow.
- My Cars:
- x 2
Synchro cones off.....
Good hub (left), bad hub (right):
Close up worn cone, the top portion is worn smooth:
Replacement has a manufacture date stamped on it, 04/02/99!
I'm to try and figure out how to reassemble the thing now......
Good hub (left), bad hub (right):
Close up worn cone, the top portion is worn smooth:
Replacement has a manufacture date stamped on it, 04/02/99!
I'm to try and figure out how to reassemble the thing now......
Last edited by evilally on 20 May 2010, 21:45, edited 1 time in total.
'96 405 1.6 GLX with 306 GTI engine on Cat cams @ 195bhp
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
-
- (Donor 2020)
- Posts: 742
- Joined: 17 Apr 2008, 22:39
- Location: Clydebank, Near Glasgow.
- My Cars:
- x 2
Ladies and gentlemen (I suspect mostly gentlemen), I present to you a super-easy way of reassembling a BE3 input shaft
A 5th gear sleeve from the spare box:
An injector deep socket:
Place the sleeve ontop of the bearing, it's a perfect fit:
Drive home the bearing as far as possible with the sleeve, then place the injector socket on top:
Then drive home the rest of the way......
The whole thing took seconds!
A 5th gear sleeve from the spare box:
An injector deep socket:
Place the sleeve ontop of the bearing, it's a perfect fit:
Drive home the bearing as far as possible with the sleeve, then place the injector socket on top:
Then drive home the rest of the way......
The whole thing took seconds!
'96 405 1.6 GLX with 306 GTI engine on Cat cams @ 195bhp
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
Its fine, its being used for its intended purpose .Gammy leg wrote:Aaaaaagh, Daily Mail!!!!!
Great work Ally, nice to see someone getting stuck into a gearbox!
D
XM Prestige PRV6 92
Talbot Express Autotrail Chinook 89
Mitsubishi L200 Trojan 14
Xantia Activa 95, sold (missed)
Service Citroen is awesome, it shows me pictures of all the parts i used to be able to buy............
Talbot Express Autotrail Chinook 89
Mitsubishi L200 Trojan 14
Xantia Activa 95, sold (missed)
Service Citroen is awesome, it shows me pictures of all the parts i used to be able to buy............
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- (Donor 2020)
- Posts: 742
- Joined: 17 Apr 2008, 22:39
- Location: Clydebank, Near Glasgow.
- My Cars:
- x 2
Don't worry, I found it in the blue recycling bin
I found the source of the problem I think. I've noticed that the roll pin on the bottom of the reverse gear shaft is sheered off
My original is on the left, fortunately I have managed to retrieve the broken bit of metal from inside the gearbox.
The one from the doner box is a different design, but it fits perfectly. I'm not sure if I should use it or not. I could try removing the pin from it, but then I might end up with 2 knackered shafts. Opinions?
I found the source of the problem I think. I've noticed that the roll pin on the bottom of the reverse gear shaft is sheered off
My original is on the left, fortunately I have managed to retrieve the broken bit of metal from inside the gearbox.
The one from the doner box is a different design, but it fits perfectly. I'm not sure if I should use it or not. I could try removing the pin from it, but then I might end up with 2 knackered shafts. Opinions?
'96 405 1.6 GLX with 306 GTI engine on Cat cams @ 195bhp
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.
'05 RenaultSport Clio 182 Cup, 102k
'97 406 1.9TD, 314k.