Why is it that a little job...

…always turns into a two day nightmare.

Okay - I know changing a gearbox isn't a "little job" but its fairly straight forward as long as you are methodical and take your time - so why is it that the last of those silly splined bolts that hold the shafts to the output flanges on the diff is not only ceased solid but also sheds all its splines as soon as you put any force on it - ended up lying underneath the car for 40 mins with a hacksaw…

Anyway - its done now so thats another job out of the way!  Guess I'd better order another one of those bolts…

I replaced ALL of them on mine as a matter of course. They are the kind of bolts you don't want to round off! Even if the bolts are in good condition, they get full of gunk which increases the chances that you are going to struggle.

Cheers
Rajan

Tell me about it!  When I swapped the engine a couple of years ago I had to cut three of them off and the one that gave up on my was one of the replacement ones.  I believe that early cars used an allen head instead of a splined bit - probably just as awkward though…

that's what makes doing your own car repairs/work fun!  :wink:

I don't know about that but I know I was exhausted when I was finished.  One of the back brakes is now bound on from standing so long - you finish one thing, two things pop up…

…so in a way my Golf is like a lawn full of moles.

I took out my broken gearbox today. I remember reading your post Steve and thought you would like to know you are not alone on the splined drive shaft bolts!!!

Here a few pictures that show how I progressed:

Ok this is how she looked at the start


This is how I delt with the last spined bolt that rounded… cover your eyes 8O



And eventually… Ta da



First time I've removed a box and I am quite proud of my self . Tomorrow my new low mileage box goes in. I hope it goes ok, wish me luck :wink:

Kins, did you source a 1600 box? They have shorter ratios than the box for the 1800 (which your car now appears to have). Be interesting to see whether the shorter ratio 1600 box gives any noticable improvement to acceleration through the gears :twisted: .

Cheers

Yup I have a 1600 box thats only done 48000. We'll have to see how she goes  :twisted: