astra g 6 speed conversion adventures

vocky

I might still have the old ones, not really sure if I kept them or not. But I don't think I have any material to make one from either.

evocarlos

Box is coming back out for the 6th gear mod and to replace the 4 crush washer bolts on the diff/drive shaft plate

evocarlos

when they said brand new originals they weren't kidding 🙂 shame there was an error with ebay not sending the order thur to there system i had to contact them to get the items shipped out 🙂

shiney! 🙂

Dave_Gilbert

nice, so box back out n split again?

evocarlos

Dave Gilbert said:
nice, so box back out n split again?

oh yes back out new bearings off just to fit these buggers lol will give me something to do this weekend 🙂

Dave_Gilbert

You really should plan ahead. Have you got to drop the new oil you just put in? I hope your reusing it if you do.

I would😉

evocarlos

Dave Gilbert said:
You really should plan ahead. Have you got to drop the new oil you just put in? I hope your reusing it if you do.

I would😉

🙂 i planned ahead i bought the new gears before i bought the oil so its still in the box it came in hehe

evocarlos

gearbox out lol the dog tried to help 🙂

he's still helping 🙂

removing the 6th gear and bearing from the main shaft

the new gear in comparison with the old

going on

and now for the bearing and gear from the upper shaft

gear comparison

nice 🙂

but then disaster (what would a good story be without disaster)
bearing snapped on refitting :confused:

it even cracked the race lol

TO BE CONTINUED.............

HarleyPete

That's a pain in the proverbial. Hope it's not hard to get a replacement one soon. At least in your favour Carl it must have been easy getting the box out.

evocarlos

HarleyPete said:
That's a pain in the proverbial. Hope it's not hard to get a replacement one soon. At least in your favour Carl it must have been easy getting the box out.

i have a snr supplier on the way home so will pop in and order one if he cant get the snr it will have to ebay where there £30 each...
tbf im glad it broke on the refitting and not when the box was reinstalled lol
the box was an absolute pain to get out the pig ring on the passenger shaft just did not want to break free and i was there rocking with the full weight of the gear box trying to get it out

evocarlos

so there was this thing

i had a go at making one

cutting and shaping

getting there

drilling and tapping do the hole

test fit

even put the square hole in it 🙂

comparison of the 2 mine^ and the original below fitted to m32's after 2007 with the uprated bearings

the new bolts in the flange

HarleyPete

evocarlos said:
i have a snr supplier on the way home so will pop in and order one if he cant get the snr it will have to ebay where there £30 each...
tbf im glad it broke on the refitting and not when the box was reinstalled lol
the box was an absolute pain to get out the pig ring on the passenger shaft just did not want to break free and i was there rocking with the full weight of the gear box trying to get it out

That's very true mate, better it broke now than when your driving along. Strange that the shaft was so hard to get out, when I did the box on my Zafira they came out easily. It's great that you have a supplier near by, lets hope he can get it, better still lets hope he has one on the shelf, lol.

KevinH

What's wrong with the original part above? or just didn't like it.

corsaZ22se

pity the bearing broke, must have been weak so like you said better that it failed now than after it was all up and running.
do you warm the bearings before fitting? freeze the shaft?
deep fat fryer for the bearing and put the shaft in freezer for a few hours. do this all the time at work when we have small enough parts.

evocarlos

HarleyPete said:
That's very true mate, better it broke now than when your driving along. Strange that the shaft was so hard to get out, when I did the box on my Zafira they came out easily. It's great that you have a supplier near by, lets hope he can get it, better still lets hope he has one on the shelf, lol.

the thing is pulling the shaft from the wheel side is quite easy 🙂 no imaging the shaft is fixed and your pulling on the gearbox 🙂 that the way i did it lol
when the guy helped me press all the gear packs back together and we were sorting what goes where he said we stock snr so you never know 🙂

KevinH said:
What's wrong with the original part above? or just didn't like it.

hey kevin mine never came with the plate it was a modification fitted to the m32 after 2006 where the box had some things changed
1st gear the output bearing and seal were different sizes and the use of snr bearings as upgraded parts at a guess the little plate is to guide oil into the bearing to help stop it falling like the older boxes that use the timken bearings

corsaZ22se said:
pity the bearing broke, must have been weak so like you said better that it failed now than after it was all up and running.
do you warm the bearings before fitting? freeze the shaft?
deep fat fryer for the bearing and put the shaft in freezer for a few hours. do this all the time at work when we have small enough parts.

well i was going to warm the bearing up but the gas bottle ran out on the heater so it was a tap it on job
i started with a 24mm socket and was working fine got it almost all the way on but the socket got jammed on the shaft so i went to the next size 27mm 2 taps and the race just shattered 🙁

corsaZ22se

been ther done that before. 🙁
hot air gun to hand all the time now. best part about where I used to work was a lathe so any drift I needed I could make in minutes. really miss that.

evocarlos

corsaZ22se said:
been ther done that before. 🙁
hot air gun to hand all the time now. best part about where I used to work was a lathe so any drift I needed I could make in minutes. really miss that.

lol i would of used the heat gun but thats now 18years old and dont work lol i was a little dubious about putting it in the oven as the retainer is made of plastic and not cast

corsaZ22se

that could end up messy? have you ever tried a deep fat fryer? fill it with the correct gear oil, smells a bit but really even heat up.

evocarlos

well that was a kick in the kabollocks £28 for just that one bearing lol

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