405 Gearbox Rebuild and Clutch Change

evilally · Post by **evilally** » 21 May 2010, 21:57

It's all good, there was enough of the roll pin left to locate the shaft in the casing. I would imagine that's all it's there for as it doesn't look very strong. Any load bearing must be taken by the bolt at the top, so I'll leave it at that. The shaft off the spare box didn't work, the box locked solid with that installed.

Post by **CitroJim** » 21 May 2010, 22:28

Well found Ally

Funny that, I had thoughts that the problem might have been connected with the reverse idler..

Never seen a reverse idler like that before!!!!

When I saw the reference to roll pins I was thinking at first you were speaking of those in the selector mechanism...

Back on the road tomorrow then

evilally · Post by **evilally** » 22 May 2010, 19:11

Good news.....ran the car up on the axle stands through all the gears and no unusual noises

Another couple of hours to put the brakes back on and sort out a few other things and she should be good to go!

Post by **CitroJim** » 22 May 2010, 20:13

evilally wrote:Good news.....r

Brilliant

Well done...

evilally · Post by **evilally** » 22 May 2010, 22:26

Thanks

Had the car out for a spin tonight, running fine. Clutch feels great, and I've got a non-crunching 3rd gear. What a novelty! Thanks to everyone for their help, particuarly Jim

Post by **CitroJim** » 23 May 2010, 07:43

Brilliant

Aren't new clutches just lovely

Light as a feather. It can make the whole car feel totally different to drive..

Gammy leg · Post by **Gammy leg** » 23 May 2010, 13:20

Terrific thread, particularly all the pictures. Great to to get such a relatively quick resolution to what was a very complex ( to me, and probably many others ) problem. I was on the edge of my seat for much of it... will he , won't he, will it, won't it !!! A real rollercoaster.
Big congratulations

Gammy

jgra1 · Post by **jgra1** » 23 May 2010, 14:36

evilally · Post by **evilally** » 24 May 2010, 09:47

Thanks guys

Glad to hear I'm not boring everyone! Before I got the 405, the most complicated thing I'd done to a car was put petrol in it. So if anyone is thinking that they wouldn't be able to do something like this, well you probably could. Just break it down into small steps and try and do a little bit every day. Before you know, it's done

evilally · Post by **evilally** » 15 Jun 2010, 21:52

Quick update, 1,300 miles since the work has been done, car running great. Did an oil change on the box today to flush out any crap, this is what came out:

Seriously nasty stuff. I cleaned everything in the main casing in parrafin before putting it back together, kind of wish I'd taken the diff apart and cleaned that as well! I don't know what on earth has been put in this box in the past

I'll do another change in another 1,000 miles or so and keep flushing 'till all the rubbish is out.

Post by **myglaren** » 15 Jun 2010, 22:12

Looks like a stewed brain

addo · Post by **addo** » 15 Jun 2010, 23:38

It may be a PTFE additive. They're considered good practice here on BE3 boxes.

Then again, it could be emulsified old oil!

Gammy leg · Post by **Gammy leg** » 16 Jun 2010, 20:37

I'm with Steve on this, definite brain matter

I believe I have been served this in France

Gammy