gearbox and clutch instalation, ne up 4 it $$$$

Wagonbloke · tinkerer Joined: 01 Sep 2003 Posts: 107

in salisbury area my mates was wonderin if ne 1 is a mechanic or had experience for puttin in a 5spd gearbox instead of a 4spd and also putiin in a clutch.

Racegem · backyard mechanic Joined: 30 Jan 2002 Posts: 987

I'd like a trip north. Smile

The airfare might not be in your budget though...

Yonnee.

mystikal21 · tinkerer Joined: 23 Jul 2003 Posts: 160

im looking for a trip aswell umm noootttttttt!!!!

tunnel vision · tinkerer Joined: 29 Nov 2002 Posts: 178

In the workshop page there is a really good post (with pic's) on installing a new clutch. I changed my thrust bearing on the weekend and found it not hard to do. I also went to the Noarlunga library first and had a look in a Gregorys and did a bit of photocopying of the clutch section. Salisbury ( out bush, lol) must have a public
library you can check out. If you have a bit of mechanical knowledge it's not that hard. Dunno bout changing the 4sp to 5sp but I reckon a friendly call to a Gem shop in your area might help. Remember to number all the bolts you take out on a sheet of cardboard and put the bolts next-to them will help too. Hope this helps ya.

Wagonbloke · tinkerer Joined: 01 Sep 2003 Posts: 107

yah cheers heaps ill pass that on but the bloke is 2 scared 2 touch his car but yah that does help cheers

Poida

My opinion...

If someone wants to attempt mechanical repairs/alterations to a car and doesn't know where to start, buy a workshop manual.

For the average spanner wielding beginner, a Gregory's is a good place to start for around $30ish at your nearest auto stop.

Now the complex bit....

The 5 speed box slides into the slot with a minimum of fuss. It bolts up exactly the same in all ways. You may have clearance trouble in the earliest (TX) flat floorpan Gemini but all the rest are compatible. The only thing you need to worry over is the output shaft has matching spline count. There are two different types, course spline (pre 81 cars) and fine spline (post 81 cars). Assuming your car is still using the original box you'll have a fair idea by looking at the VIN tag. Look at the output shaft on the donor box, then remove the tailshaft from your car and see it is the same. If it is proceed.... if not go out and get yourself a tailshaft to suit the donor box. It's not much fun to find the difference after you have done the swap. Be sure to get one the same length. There are two lengths. short for sedans and longer for wagons and vans.

The clutches are the same in all rear wheel drive Gemini models.

One last thing to watch... if the donor box is from a petrol car no problem. If it's from a diesel car, you'll need to change the speedo driven cog. The diesel box can be identified firstly by the steel rear bearing carrier housing (the thin piece of the case in between the main case and the rear extension housing) and secondly by the wide ratio fifth gear. Petrol boxes use an all alloy housing.

Be sure to adequately support the box when you are taking it on and off... It is heavy enough to hurt!! It will also damage the clutch plate if you let it hang with the input shaft still inserted in the clutch plate unsupported.

It's really not a hard job at all.

I could write you a step by step guide but Gregory's have done it already!! Get a copy of the book. It will prove a handy friend indeed.
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