John Vine Posted November 15, 2021 Share Posted November 15, 2021 Having recently completed this exercise in order to get my gearbox out for its rebuild, I thought it might help other Duratec owners if I were to record the steps I went through.These are now set out in a newly published Technical Guide. Comments, suggestions, brickbats welcome...JV Link to comment Share on other sites More sharing options...
Leadership Team Shortshift Posted November 15, 2021 Leadership Team Share Posted November 15, 2021 Great work John. Very helpful, very clear, very useful - well done! James Link to comment Share on other sites More sharing options...
Area Representative Geoff Brown Posted November 15, 2021 Area Representative Share Posted November 15, 2021 Good explanation on 'how to' JV.For those with a dry sump there is of course extra work. I found that the thinnest foam pipe insulation is excellent protection for the top angled chassis bars.What about these 'extras' ? Inspect & replace engine mount & gearbox rubbers, clutch, clutch release bearing & slave cylinder as necessary. For the hidden components it would be a mistake not to then have to remove the engine/box combo again. Link to comment Share on other sites More sharing options...
John Vine Posted November 15, 2021 Author Share Posted November 15, 2021 Thank you for your kind words, James.Good points, Geoff. I'll add something about foam, and also re your extras. I inspected mounts and rubbers, but didn't inspect the clutch as it was replaced in toto only 13K miles ago. Perhaps I should have?JV Link to comment Share on other sites More sharing options...
Jonathan Kay Posted November 15, 2021 Share Posted November 15, 2021 Excellent. Congratulations.How about listing tools near the top?Jonathan Link to comment Share on other sites More sharing options...
John Vine Posted November 15, 2021 Author Share Posted November 15, 2021 Good idea, Jonathan. That'll be a memory test as well.JV Link to comment Share on other sites More sharing options...
David Brown Posted November 15, 2021 Share Posted November 15, 2021 Just to mention, ensuring clearance for engine hoist around front Axle stands can be tricky. Certainly on my CSR which is an SV. Link to comment Share on other sites More sharing options...
Alan Reeves Posted November 15, 2021 Share Posted November 15, 2021 Nice one JV Link to comment Share on other sites More sharing options...
Hampshire West AR Posted November 15, 2021 Share Posted November 15, 2021 Very good John. I would always disconnect the battery after removing the bonnet and nose cone as a 1st step.Nick Link to comment Share on other sites More sharing options...
Jonathan Kay Posted November 15, 2021 Share Posted November 15, 2021 And that the crane, the lifting eyes and the torque wrench can be borrowed: https://www.caterhamlotus7.club/guides/parts-accessories-and-spares/equipment-loan-registerJonathan Link to comment Share on other sites More sharing options...
John Vine Posted November 16, 2021 Author Share Posted November 16, 2021 Re #7: Interesting point, David. Would a single central stand work with a CSR? I was thinking that there's a vertical chassis member there? I guess that wouldn't be such a good idea on an S3.Re #8: Thanks, Alan!Re #9: Thanks, Nick. I'll include that.JV Link to comment Share on other sites More sharing options...
David Brown Posted November 16, 2021 Share Posted November 16, 2021 John, I seem to remember once last year, I had the engine/gearbox in and out three times, that I used a central support while manuvering the lift in and out and replaced with two stands when working on the car. Link to comment Share on other sites More sharing options...
John Vine Posted November 16, 2021 Author Share Posted November 16, 2021 Thanks, David. I think I'll add a comment to that effect.JV Link to comment Share on other sites More sharing options...
BBL Posted November 17, 2021 Share Posted November 17, 2021 Thank you, sir! This could be very useful to many.rutabaga Link to comment Share on other sites More sharing options...
7 wonders of the world Posted November 17, 2021 Share Posted November 17, 2021 Nice one JV, Might be worth noting that your using standard CC engine location, those of us using the Raceline engine mounts and bellhousing benefit form and extra inch of clearance meaning the engine pops out in an S3 without the gearbox easily - particularly useful is your garage roof is quite low, or like me you have a storage area in the pitch. Link to comment Share on other sites More sharing options...
John Vine Posted November 18, 2021 Author Share Posted November 18, 2021 Thanks, folks.JV Link to comment Share on other sites More sharing options...
David Brown Posted November 19, 2021 Share Posted November 19, 2021 Forgot to mention that if you have electric door openers you should ensure the car/engine lift are off centre to ensure clearance when lifting. Link to comment Share on other sites More sharing options...
John Vine Posted November 20, 2021 Author Share Posted November 20, 2021 ...electric door openers...I take it you mean the garage doors rather than the CSR ones. JV Link to comment Share on other sites More sharing options...
Area Representative Geoff Brown Posted November 20, 2021 Area Representative Share Posted November 20, 2021 One of my area members (North Wilts) has just successfully fitted his Duratec/gearbox assembly in to the chassis while situated in the lounge/living room !!Don't ask !!JV - Maybe an addition to your guide is 'the job can be accomplished even in your lounge or living room' Link to comment Share on other sites More sharing options...
John Vine Posted November 20, 2021 Author Share Posted November 20, 2021 JV Link to comment Share on other sites More sharing options...
John Vine Posted December 6, 2021 Author Share Posted December 6, 2021 I've just uploaded a revised version of this Guide.I hope I've included all your helpful suggestions (yes, even yours, Geoff!), but if you see anything I've missed or got wrong, please say.JV Link to comment Share on other sites More sharing options...
Support Team Shaun_E Posted December 6, 2021 Support Team Share Posted December 6, 2021 Great work John.If anyone else has written or would be prepared to write a guide then please contact me. It can be as short or long a job as you like but if you think a fellow owner (especially a new one) could get some help from your experience then please give it a go. John has set the gold standard with step by step instructions, photographs and lists of parts and tools but any documented tips or instructions are useful.Shaun Link to comment Share on other sites More sharing options...
John Vine Posted December 6, 2021 Author Share Posted December 6, 2021 Thank you for your kind words, Shaun!JV Link to comment Share on other sites More sharing options...
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