Manual Gearbox removal 2.0 lt T5

[Sunny43.5]

Hi guys a question for the all knowlegable types out there , has any one removed the manual gearbox from a 2.0lt petrol T5 2005 model if so rough idea of how long to R&R approx . I have decided that the clutch has reached the end of its long suffering life and needs replacing post haste . Are there any special tools required and is it a B of a thing to remove , I am quite handy as have done a whole two car engine transplant on the sons 97 T4 last year his was diesel and now petrol . Any suggestions or hints would be appreciated Howard .

[Transporter]

It's 4.6hours remove/install and replace clutch.

[Umai Naa!!]

Pull the subframe out.

You'll need to support the gearbox end of the engine, though.

Once you get the subframe out, the rest is surprisingly simple.

[Sunny43.5]

Thanks guys I plan to do it on the weekend as I,m off Moto Cross riding tommorow and be home Saturday . the throw out bearing started screaming today so just as well I picked up the parts this am . Will give an update when finished .

[Sunny43.5]

Okay job done not 4 . 6 hours please remember I am not a mechanic around 8.5 hours I do have lots of tools I did not have enough trolley jacks and supports etc ! . Whilst I did not totally remove the support frame just lowered it around the ds front and both pass side then let it tilt down . Support under motor worked fine pulled box out to the side and left it rest on frame . Clutch was apiece of cake [ wife was curious why the garden rake handle is now 6 inches shorter , hmmmm . Now the throwout bearing was absolutley shot the facing side of the bearing was gone !!!!! bearings were 5 minutes from total sieze { no wonder it was screaming on Thursday } Reassembled and no left over bolts joy oh joy .
Only hitch no big deal got brake pad sensor wire trapped and broke off , will fix later when brake pads redone , possible power steering leak found at point where two pipes go into side of steering column now there was a slight damp patch on engine plastic cowel when removed but not sure if it was like that before I started as at one point while trying to refit the box I got the rear engine mount caught on one of the pipes and it may have bent it slightly down again can be sorted later . Test drive unreal had forgotten what a normal clutch felt like as the pedal now goes to the floor with out feeling rock hard near floor plus it engages smoothly from just above floor so nice . Would I do it again HMMMMMMM no I dont think I will have the van by the time it needs redoing . I have always loved working on my own cars as I grew up around my Uncle who was a mechanic and I used to help with my dad doing stuff from around 10 years of age . Now I am 60 the old back can only take so much punishment [ and it didn,t help that I spent Friday and Saturday riding my Honda CRF 250 at Wyaralong MX park 25 km enduro trail rides and lots of action on the Moto Cross tracks ] Thanks again for the hints Umai Naa it made a world of difference . Howard

---------- Post added 21-05-2012 at 06:29 PM ---------- Previous post was 20-05-2012 at 10:34 PM ----------

Just an add on to this post today the engine starts to play up coincidental I am not sure ? idles perfectly accelerate perfectly but when coasting it hunts up and down giving a kangaroo hopping effect at low speeds . Now the engine light has come on any one with an idea ? Regards Howard