big furry m**ge

[Adam-D]

this is a new project, that ii dont know what do with, keep or sell.

got it and the gearbox is hoofed, so, thats the first job.

1600 sport, 50 odd k on the clock, network q car so it does have history
"i-e vaux put a new engine in at 38k due to belt failiure"

so.

gearbox removal

take the battery out, and the tray
10mm for the clamps, 13mm for the battery and tray



rusty tray, i will be rubbing it down and making it non rusty.




unbolt and move over the sai pump
2x 13mm




take the wheels off, jack up, and put on axel stands
17mm






undo the ball joint bolts both sides
2x 13mm



then pop the ball joints out, if you damage the rubber like i did, replace them




undo the clutch cable




unplug the speedo plug


and the reverse plug


take the linkage pin out, press the tab in at the bottom and push it upwards





and the linkage pivot pin
push the edges out, and lift up


then start takeing the starter off, this is tricky as there are some nuts you cant see, the wiring is in the way, and one nut is actuall a double, nut/bolt
4x 13mm and 1x 10mm using a deep socket for the 13mm






grab yourself some food/drink, and have some




sort of the middle of this pic, is the rod to linkage bolt undo it and seperate them
1x 13mm


then pull the shafts out
grab an pull





and by now you should have 2 things, a tray to catch the fluid, and you should have cut yourself at least once



then start undoing the block to box bolts
array of 19mm, and 15mm




there is one at the top you have to take the box breather off, and use a 3/8th drive as a half inch wont go in,
19mm


now the box should have started to split away


so get a jck and a bit of wood, place it so it does not hit anything like the sump nut etc and take the weight of the engine with it


undo the front and rear box mounts
3x 15mm at the front


and 2x 18mm at the back



now lever the box away from the engine


and



and heres the clutch




now due to me not having the new box to go on, or the clutch has not arrived, most jacks creep down over time, so give the engine some extra support with a axel stand and some wood




now your done, have a celabratary double decker bar and some tea.

[Adam-D]

while i am waiting for the new clutch and gearbox to arrive, i thought i would change the pollen filter.

so

unscrew 2 screw and lift off pass side


pull off the rubber seal


unbolt wiper arms
2x 13mm


and unscrew the other 2 screws and lift out the drivers side scuttle panel


there are 2 big ass plastic nuts, i undid with my fingers, you may need a big adjustable spanner


then pull out 2 little "normally yellow" clips and lift out the scuttle tray




then lift out the old filter from here


i decided to clean out all the leaves and crud in there so


1x 10mm and im taking the tank out


slide and lift out the way


when clean give it a bloody good rinse




then i cleaned the panels down to



then OH NOES--- !!RUST!!



so, time to sort that
120 grit to rub down, krust to treat the panel, etch primer to prime and seal, black for colour and waxoil to protect


primed


painted


i lube'd up the wiper linkage aswell



fitted the new filter


then clipped the lower panel back in and the washer tank bolted down,
copper greased the spindles and the screws
re-fitted the upper scuttle panel, again greaseing the screws


then put the arms back on again using a little copper grease.

and put it back together

[CorsaTD]

good love too see projects like this they give u the info u want to know lol

[PaulW]

Fun times dude

Did you get it running today after fitting the aux belt wrong and the gearbox you got from me?? How's it going on that front, should be a solid box as far as I'm aware...

[Adam-D]

heres your answer paul

right this is a 2 day update in one hit, ill do it as i did it.

as i waited to get the new clutch etc, i decided to do the timing gear then i got the cltuch and box so did that

then did the front brakes, here are the pics
some parts there arnt as many pics, but i was flat out working on it.

i used the haynes for reference on torque settings and for reference. no second guessing etc.
and i used a locking tool for the cams



first undo the airbox and remove it


taking the aux belt off, using 13mm spanner, and slacken tensioner and remove the belt


lobbing the aux belt


removed top cambelt cover
3x female torx


removed lower dirt shield
2x t20 torx and 2 8mm bolts


then the fun part, to crack off the lower crank bolt i had to lock it in a gear, and put the brakes on,
problem
gearbox was on the floor


so with the help of a iron bar


the fly was locked



then i cracked the crank bolt


and took off the pulley


then spun engine till tdc was found and locked the cams


removed the lower cover


checked all timing marks




undid the tensioner


and off with the belt


unbolted the tensioner


the water pump had me puzzled a little it has a timing mark to the block



but the new one


didnt

old pump out



old and new pump



the new pump didnt have a timing mark but after a few mins it was clear that the notch is for the top securing bolt and the pump will only fit one way

all good i used some sealent, mounted the pump and used some loctite on the bolts


torque'd up all the new rollers and pump


and fitted the belt


spun the engine over by hand and checked the marks.

by now i was stuffed and called it a day, next day i got the new cltuch and gear box. and the drive belt

new clutch, pressure plate, and release bearing


new and old box


also, fitting a box in a garge, on your own, isn't good for you. trust me.


i cleaned the flywheel down


and fitted the clutch


the next bit involved lots and lots of swearing, hurting myself, trapping fingers, bits of wood and 2 jacks.
there anrt many pics, as i threw my phone aswell :!
main part if you fit a box with engine in situ, make sure the coolent galley solid pipe is clear, as its a badger to move it once the box is half in.

the one and only pic.



box being bolted in


connected the clutch and i filled it with some gm transmission oil


put the linkage and speedo back together


connected linkage, fitted starter and mounted rear mount


connected reverse sensor


and checked it all worked


then onto the tidy up jobs,
fitted the new aux belt



as stated i stuffed one of the ball joints, so i replaced them both
undoing the old...


new and old


and then fitted it.


then

as the car has been stood the disks have rusted to a point where i wouldn't consider them safe, they looked like new disks, but the pitting was quite bad, so they could shatter, so off with them


new disks,


hub was a bit manky


so got the wire brush out


greased the disk to hub mating face



hammerite an a brush



then rubbed down the calipers, greased the moving parts and sliders
fitted it together and painted them




then dropped it back on its wheels
last job today was to sort the battery tray as it was rusty
so heres one i made earlier



next job is tidy up rear brakes cos its been stood and there stuck on a little.

[Adam-D]

right, rear brakes time, they were sticking
and it turned out to be the cable.

but i re-greased the bearings, cleaned the shoes, and painted the drums while i was at it.

heres some pics

first up the fuel light came on, so i got 10 litres of optimax



then the brakes
first pop the hub nut cap off


then pull the split pin out, i used new ones on re-assembly


undo the centre nut


then remove the toothed washer


and pull off the outer bearing race


pull the drum off


i then cleaned the shoes down and greased the self adjusters and put new grease on the bearings


bolted it back together and painted the drums


while that was drying i decided to free up the bias valve


i also changed the fuel filter
undoing the filter clamp


pop the little clips


and refit new filter, remebering to put the rubber surround over the new filter

[Adam-D]

went in for its mot, failed on a "rough feeling bearing" on the back

so

a hour later i had fitted a new one

and she now has a mot yay

old bearing tapped out,


old and new bearing


new bearing in


then i got a 2nd bearing to make sure i did them in a pair, so both side have been done

[Adam-D]

gave it a clean today,
ive never had to take off the rain gutters on a corsa, till today

heres an after pic





and the before pic and the reason i un clipped the gutters




right the deadlocks didnt work
this is a very very common problem with corsa b's
its down the the lock ring outer edge brake-ing off, and thus not activating the micro switch
so for less than a tennner i got one and fitted it.

the new lock ring


pull off the mirror cover


recover the white pop clips and clip back into the panel.


lever off the handle cover and pop out and feed throu the mirror switch


unscrew the 3 screw holding the handle in place and remove


then unscrew the 8 screw holding the lower pocket in


and detach/unclip the wire plugs


then unscrew the 3 screws holding the door card in and lift it up


peel back some of the weather strip
have a fish around the bottom of the door
you should find the remains of the lock ring


undo the 2 10mm bolts holding the rear window runner in, pull it to the front of the door and downward, it will unclip,


and them undo the 2 10mm holding the rear alu lock plate in


unclip the micro switch, and the yellow tab and pop the bar/rod out


this is where the new ring goes


unclip the circlip and lift off the top bit, the next bit is the ring, pull it off carefully


then clip in the new ring to the top bit
and there is a tiny black bearing it goes in the small hole/gap
then put back on and reclip the circlip back in





this is what you have removed


then put it back in the door remembering to reclip the bar/rod in and the micro switch


put the handle and window runner back in

tape the weather strip back on



and put the door back together.


your dead locks now work.


my bro like to polish/detail, so i let him loose with some of his fancy blue polish and

the bonnet


and reflection

[chubbybrown]

Very good pics and follow through.

Even though I was only looking how to do the ball joint,I ended up reading the whole thing.
your are to be commended.
Thanks

Roy

[fatboi567]

how much does your brother charge for a correction??

[scorpiotn1]

Great detailed pics and information.

[Adam-D]

im glad this post is helpfull.
my brother does it as a hobby on his cars
can ask him, but he has limited compounds for certain colours

[dupko]

Thanks for that pics and comments.

[Chrex]

flippin eck - who dug this up?! I remember workin on this wit Ad - seems like a lifetime ago. I was building my GSi at the time. Fun times

[tonyhugill]

any chance you could get the pictures back on the gearbox removal post right at the beginning of this thread?, ill be doing my clutch next week so i need take the box out and i have never done it before