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Location:
South Australia
Registered:
July 2002
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ST165 gearbox won't come off
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Sat, 23 April 2005 02:23
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Okay I've somehow (via no small miracle) managed to get all the bolts that attach the gearbox to the block and then I guess the transfer case as well. Yet the damn thing still won't come off.
Is it likely just the seal is really strong? OR is there some kind of internal clip or seal or something within the transfer case that will cause the gearbox to stay on? As far as I can tell I should just be able to crack the thing off but it ain't happening.
Yeah I'm sure I posted something about this before, but after checking several pages of the Tech section and doing a search, and looking through my old posts I couldn't find it. So I guess I'm spamming but oh well. My dial-up CBFed downloading another twenty pages of stuff to find the info.
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Location:
Brisbane, Queensland
Registered:
January 2004
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 02:46
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You more then likely have missed a bolt.
When i tried to pull the gearbox off my ST185, i missed the 12mm(ithink) bolt which is hiding on the bottom side of the engine right up behind and under the transfer case.
After i got that bolt, pryed the gearbox off with a few screwdrivers and a large bar.
http://ugbox.net/~lance/GT4/Technical/Manual%20Tra nsmission%20Manual/removala.pdf
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Location:
South Australia
Registered:
July 2002
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 02:59
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I'm pretty sure I've got all of them, I guess I'll just have to smack the shit out of it and use screwdrivers and pry-bars etc etc until it agrees with my point of view.
And if I break something then it needed replacing anyway 
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Location:
Brisbane, Queensland
Registered:
January 2004
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 03:03
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Well in essence once you take the stays off, there are only 4 bolts holding the engine on. 3 on the front, and 1 underneath. The 1 underneath is deceptive and i missed it several times.
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Location:
South Australia
Registered:
July 2002
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 03:35
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Are you talking about the transfer case? Cause yeah I just found one that attached the transfer case to the gearbox that is basically inaccessible - it's underneath and it's wedged between the engine and the transfer case. Somehow I've managed to get a 17mm socket in there to get the nut but it's hella torqued up and my hands are too busted up from doing the other bolts for me to be able to do it today. So I think I'll tackle it tomorra once the WD-40 has soaked in a bit.
Did I mention I'm doing this with the engine in the car? Or did I leave that out 
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Location:
Brisbane, Queensland
Registered:
January 2004
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 06:30
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I think its a 14mm, cause the 3 large foundmounts are 17mm each.
Its wedged right up there, but it isn't on the transfer case, its between the gearbox and the engine block itself.
Good luck with it in the car, it is alot easier out of the car. Believe me.
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Location:
sydney,nsw.oz.
Registered:
July 2002
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 07:06
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| FWDboy wrote on Sat, 23 April 2005 12:59 |
I'm pretty sure I've got all of them, I guess I'll just have to smack the shit out of it
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Buy yourself a rubber mallet
Very handy when doing this sort of thing !
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I Supported Toymods
Location:
Sydney
Registered:
December 2002
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 07:37
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You will need to tilt the gearbox or engine so that the setup is closer to the factory angle.
If you are trying to do it with the gearbox on the ground and the engine lifted with an engine crane you will have a very hard time.
Use some blocks of wood or something under the gearbox to get it at the right angle with respect to the engine and then it should come off fairly easily.
The reason for this is the gearbox will be hanging off the locator rod thingies.
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I Supported Toymods
Location:
Sydney
Registered:
December 2002
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Re: ST165 gearbox won't come off
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Sat, 23 April 2005 07:38
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| FWDboy wrote on Sat, 23 April 2005 13:35 |
Did I mention I'm doing this with the engine in the car? Or did I leave that out
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I didn't read this before... it will be a bastard of a job with the engine still in the car!!!!
Especially if the car isn't up on a hoist or something.
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Location:
South Australia
Registered:
July 2002
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Re: ST165 gearbox won't come off
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Sun, 24 April 2005 00:59
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Whatever bolt I have managed to find it's on the back of the gearbox (east side) and it's holding the transfer case on to the gearbox. I'm 100% positive every bolt between the ENGINE and the gearbox is off. The transfer case is a different story, I'm fairly sure that this is the last one, it's hard to tell when you can't even see the bolt and you have to use your hands to find it
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Location:
Brisbane, Queensland
Registered:
January 2004
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Re: ST165 gearbox won't come off
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Sun, 24 April 2005 04:35
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um, this might sound stupid, but since your doing it in the car, have you undone the gearbox mount to the chassis?
Make sure you support the engine, as the gearbox takes most of the load.
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Location:
Canberra
Registered:
April 2003
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Re: ST165 gearbox won't come off
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Sun, 24 April 2005 09:28
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man, if I was you I would pull the engine out of the car and take the gearbox off it then slap it all back together, cause getting it off is a lot easier than getting it back on, (if your having this much trouble now, imagine whats its like to get it back on in the car), have you got something to support it if you get it out, the box weighs about 150kg, the bit I find it gets stuck on even out of the car is, because the tranfer case goes around in behind where the mountings are to the block, you have to twist it at a very awkward angle to get it over it. and i don't know if you could do that with the chassis rail there blocking it.
the tranfers case itself doesn't actually bolt to the engine, it just rests on the bracket on the back of the block
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Location:
Brisbane, Queensland
Registered:
January 2004
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Re: ST165 gearbox won't come off
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Sun, 24 April 2005 10:13
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my thoughts exactly. getting the gearbox is a right cunt.
pull the whole thing out, your halfway there already.
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Location:
Canberra
Registered:
April 2003
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Re: ST165 gearbox won't come off
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Sun, 24 April 2005 11:49
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yeah I know all about it, I have had to take mine on off 3 times now 
I was told a little trick to get it back on, cause the 2nd time i was at it for almost 3 days to get it back onto the engine (out of the car) the easiest way is to tilt the engine up onto a tyre but have the pulleys and cam covers on the tyre, you then use the hoist to lower the gearbox onto the engine. Works a treat, got the box onto the engine in about an hour or so.
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Location:
Brisbane, Queensland
Registered:
January 2004
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Re: ST165 gearbox won't come off
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Sun, 24 April 2005 12:23
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even easier is what toobs describes.
The gearbox remains flat on the ground, and tilt the engine so its at its natural position that it is in the engine bay. (10-15degrees tilt back)
go in on the engine from the angle, sliding the transfer case past the engine box mount, adn getting the input shaft to line up directly with the spline. straighten the gearbox, and slide it in. Once the splines are lined up, its only a 5-10mintues job of cursing.
Big thanks to spectral for showine me how do it.
Gearbox off while out of the car is easy, there is just pricelss room to work with. Remove the 2 stays behind the engine which attach to the tranfer case. remove the bottom flywheel gaurd, and don't forget that bolt which is hiding up under there. And then undo the 3 bolts on the front of the gearbox, get your trusty screwdriver, pry them apart, and then slide it out, and angle it off, reverse of install. Again only a 5-10minute job.
And when you look at it, it makes sense to drop the whole package out. Since the gearbox basically holds the whole package in. By the time you get it to the stage of removing the gearbox, your only 1 mount, and a few hoses/wires away from dropping the whole lot out.
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