replacing a 200 tdi gear box

[burgerman]

Apart from beingg F***ing heavy any tips (apart from "get someone else to do it")   its a 200 TDi manual box and should be a straight swap for the same ??   we are reasonably sensible with a spanner?  so any tips/pitfalls/offers of help?? plan to do it the weekend after next (weather permitting)

[chris9119]

Ummmmmmmm, done a couple of those this year......

Due to the weight, etc, I would recommend that you fit the gearbox first and then the transfer box.

You'll have to jack the gearbox/engine down to make it easier to locate the transfer box.

Assuming you are not doing it in a fully kitted workshop, its going to take at least three-days and you'll need three people to get the boxes into position.

Chris

Note: make sure you spray all nuts/bolts over a few days before doing and make sure you have some spare N&B's.....  :idea:  

[bilge rat]

did mine the same as chris, as well as being heavy all the weight is offset. its only a few more bolts to take the transfer box off. when you refit i made a couple of dowls to position the transfer box to gearbox. alan....

[Dr Neil]

i've done a few of these too!
Are you replacing the transfer box aswell? If so you can do it as one unit though has been said it is heavy!! If doing both together the way i found easiest is after undoing the inside and removing the gearstick start underneath.Once you have removed the props ect and the frontpipe,put a trolley jack under the transfer box and remove the gearbox crossmember,once that is removed get an axle stand/jack to support the weight whilst you reposition the jack onto the flat bracket under the now removed crossmember(if wanted you can secure the unit to the trolley jack with a ratchet strap,though i didn't).You can then lower the complete unit and remove all the bellhousing nuts/bolts(not forgetting the two bolts for the clutch slave cylinder).It is then just a case of handling the unit backwards enough to clear the clutch and lower it down.
It is best if you jack up the vehicle to gain clearance underneath so as you can remove the unit still on the jack which makes life alot easier.
If you haven't got the equipment to get the vehicle high enough to do this then you will have to slide it off the jack and man handle it out.When it comes to fitting the replacement slide it under the vehicle then feed a large ratchet strap under the unit and roune the front to rear chassis sections and ratchet it up so as you can get the jack under it.As the Haynes manual says refitting is the reverse of removal.
Myself and Dave did his within the day though all the bolts ect. had been out before.
Please be very careful when actually manouvering the unit as it is very heavy!!!!

hope this helps

Neil....