Hey Guys Im new to the forum so hopefully i do everything right. Just bought a zx about a month ago and was running ok until the gearbox buggered up on me. Wont go into reverse and the synchro between gears is not great. Im in the middle of taking out the gearbox atm and am a little stuck. Have taken off exhaust system, drive shafts, start motor, disconnected gear lever from gearbox and have got all but 2 bolts out of the bellhousing. I cant figure out how to get the top two bolts out as i cant see them and cant get any of my tools up there. I also cant see how to get the leaver that the clutch master cylinder pushes against out at the bottom of gearbox. I have taken out rubber boot but cant see how to take out lever. Also it may seem silly but am also having difficulty disconnecting the three electrical plugs to the gearbox. Any help would be much appreciated. Cheers Ben
Ben, You can get to these with a long extension (I've got a 50cm 1/2 inch drive one). You might need a uni joint and a few smaller extension to get at it. Remove the transmission mount, and let the engine rock back on its mounts. I have also had success with removing all turbo intake piping and jacking up the gearbox form the back, pushing engine forward and putting an arm down the back of the firewall from the passenger side. Its a tight fit, but works. A ratcheting spanner makes life so much more pleaseant while working on these cars. It's all about the angle of the engine dangle
I use two 1/2" 12" long extensions and one uni joint with a breaker bar on the end. +1 to ratchet spanners
What you want Like mitch said, undo the rear transmission mount to let the back of the box drop down, Get in over the top of the box from the rear. Don't forget your earth strap when putting it back on. Clutch lever just pulls out, held in by two spring clips, take off the slave cylnder first. Electrical plugs are the same all over the car, just push the little spring tab down and pull them apart, probably just stuck from road grime etc.
Drain ghte oil from the auto box first. If you pull the prop-shaft out it leaks everywhere. Don't ask me how I know.
Cheers guys Big help thanks a lot Took you guys minutes to tell me what the mechanic couldnt or wouldnt when diagnosing. Am very pleased with forum. Ben
wish I thought of doing that while removing my gearbox! I copped a few knocks to the head after the socket would slip off the bolt head
