how to take appart a manual

[millsy]

hey, i have nearly finished my tip to manual (i will do a FULL diy writeup, i have been taking pics in the process, and try finish off jonowong's post) at the moment i am trying to install my lsd from my gpvr tip into the manual (i have done it before a year ago from gpvr tip to gpx tip, which involved changing over the large gear attached to the head of the lsd) so i know what im dealing with, just one thing, i cant get the manual box open..

any tricks? i undid all perimeter bolts, and can open the box up only 2 or 3 centimeters all round (obviously caught on a shaft of something) i did the snap ring in the service hole, i undid the shifter unit, undid those large bolts on top, undid pretty much everything and cant budge it open past that 3 cm mark, and thats with a cold chisel and mallet, so any tricks? like has to be in 2nd gear or reverse or neutral? or take out that gear that you can access at the very bottom service plate?

i guess i can do a diy for the lsd aswell, so your help will help many hopefully. thanks

[FTO-BOY]

I think this post is specifically for bennoz haha


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I am here: http://maps.google.com/maps?ll=-34.062678,150.801093

[Bennoz]

Check the snap ring mate. Sometimes it looks like its off, but its not. Push the casing back down & have another shot at it. I would have also suggested the 2 case bolts that undo from in the bellhousing area, but that wouldn't give you 3cms, you'd get nothing. Also, yes you have to pull the sump plate off & remove the reverse idler gear.

As far as what gear it should be in, the manual says neutral, but I've inadvertently done it a couple of times in other gears too. Didn't seem to matter. Just as long as the selector mechanism is removed completely.

Oh & here's a DIY someone prepared earlier

http://www.scribd.com/doc/38071418/Fto- ... -to-Manual

[millsy]

yeah got it now, it looked like that reverse idler gear could have just slipped apart from the ones its conected to, but turns out you do have to remove it, thanks, my bad. and for the record for every one else, it doesnt matter if you are in gear or not to take it off, but according to the fto manual (which is quite vague in how to install, as it shows no locations of bolts and little annoying things which in theory is pretty straight foward) you need to shift the 3-4th and 5th-reverse colums "up", so it could be important when putting things back

also i got my full tranny conversion (everything needed, tranny, shifter, clutch ect) for $300 (and $60 postage), 6 months warrenty aswell, so il let these guys know if anyone else needs one, although they screwed me over on a 5speed tip for 6 months (making up excuses every week "yeah it is on a container now, blah blah". so i think they r doing it so i dont slam them, as i was going to take legal action.

so yeah, il see next time i call how much their next manuals are going for

[Bennoz]

Nice one

May as well do the input & output shat bearings while you got it apart. Its effectively a reconditioned box then!

[millsy]

just one last question mate. starter wont tick over after the manual tranny is in, as if it has to be fooled that it is in park or neutral. done some wire tracing on the handbooks, apparently there is an ignition wire for manual and one for auto (auto one goes through the inhabitor switch = P,R,N,D,-,+ switch and then goes to engine ecu/starter) (manual just goes straight through to the ecu/starter)

how has people gotten around this? i thought people didnt have a problem with this even though they were anticipating it. which wires can i cross on the plug of the switch to make it think its in park? and that should make it work shouldnt it?

[Bennoz]

Join the thick black with red & black with yellow wires from the big plug