Thread: Freelander 99 2.0TD Manual - Cant remove the gearbox

Sorry but I cannot offer anything more - except attached is the Gearbox, IRD and Driveshaft sections from the RAVE Workshop Manual - maybe there is something in there that can help.

Garry

Thanks for your help, I will work through this file and see if I will be able to get the gearbox off. If not then will probably need a mobile mechanic to help out.

The gear box can be removed with the outer race of the CV joint still in. it holds nothing but itself in

Finally got the gearbox off and clutch replaced. Thanks to all that helped. Now trying to get it back on

Had to lift the pipes out of the way to move the gearbox into correct position. Moving it just by hand, it still left about 2-3 cm gap between the engine and gearbox. I assume this is normal as the gearbox also did not come off very easily?

Is it OK to insert the bolts and start pulling it in by tightening the bolts? Looks like when the gap is about 1cm then the rear side bolts almost stop moving and its very very hard to tighten them further. Front bolts have no issues.

Should I just keep tightening the rear bolts by force or could there be something wrong and cause damage inside?

So why wouldn't the box come off??

I have never had a freelander box out before but have had to use bolts as you have suggested to put other boxes back on, but - only light force was required, never needed to have them really cranked up so if it is not going on relatively easy I would say that something is stopping it - maybe the gearbox splines - try putting a little pressure on the bolts and stopping the gearbox from turning and turn the engine - when the splines line up the gearbox should move in towards the engine and from there tightening the bolts should see the gearbox move in steadily - you need to apply equal small amounts of increased pressure to the bolts - not tighten one side only.

I can see this job fighting you all the way.

Garry

When taking it off, it did end up being another bolt in there that was holding it. It was the "secret" bolt that was from the IRD side. Thought I got them all but I didnt.

Now when putting it back on I did try to get the bolts on from all sides and fasten them all step by step to keep the box straight. So now its about 1cm away from all sides.

I can feel theres not much pressure holding it away at the front side but the rear side bolts got very very hard to fasten. Could it be that the shaft from IRD side has not lined up and a part of it is holding the box away from it? Cant really see any splines that could hold it back at this point.

I have had to take IRD out though and when puttinh back it needed pulling up gently with the bolts into the gearbox housing.

I guess you have been naughty in an earlier life.

Garry