Finally Got My Old Pulsar Back!!

Taking transfer box off is by far the easiest way if just need gearbox removed for clutch or box overhaul & makes gearbox removal same process as any front wheel drive box removal in basic procedure. Not that hard a job & with good hand tools & decent work area things are easier.
Most people struggle due to poor tools & less than ideal work area then the simplest of things can become the impossible :-S Good to see an R getting some love though :-)

glad to see you've got it out and having it rebuilt, much better in the longterm although dearer initially (if they need any parts then give me a holler as weve a few spares in stock)

ive always found it easier to withdraw the diff and leave outer case bolted to block, then its just like doing box from a fwd car.
all depends though sometimes if theres some niggly things need sorting on the back of your engine, clutch master cylinder or anything like that then you just aswell drop the lot and do it all in one go rather than battling to get into tight spaces

I used to just drop the whole lot only takes 2 hours if you know what you're doing.



Rob

good clean looking car sure you need something to do over the winter

Rich has collected the box (it was in the shop for about a week and a half) it needed a whole bearing kit, 3rd and 4th gear synchro, just need to sort out a clutch fork mod, is it really worth our while doing this? Have seen pictures of modified clutch forks, so it doesn't look too hard a job to do with the mig welder

Mr B wrote:Taking transfer box off is by far the easiest way if just need gearbox removed for clutch or box overhaul & makes gearbox removal same process as any front wheel drive box removal in basic procedure. Not that hard a job & with good hand tools & decent work area things are easier.
Most people struggle due to poor tools & less than ideal work area then the simplest of things can become the impossible :-S Good to see an R getting some love though :-)

 
 
He is glad its out, just tight bolts etc and being freezing outside!! Its good that he is a mechanic by trade so has lots of tools etc  
 
Yes its getting lots of love again, its like its never been away  

yep definitely worth doing kerime
weve sold loads of them and only ever had one failiure that I know of and that was because of a collapsed bearing putting excess pressure on one side of the fork

he could knock one up in under an hour

[quote="GTI-R US"]glad to see you've got it out and having it rebuilt, much better in the longterm although dearer initially (if they need any parts then give me a holler as weve a few spares in stock)
 
ive always found it easier to withdraw the diff and leave outer case bolted to block, then its just like doing box from a fwd car.
all depends though sometimes if theres some niggly things need sorting on the back of your engine, clutch master cylinder or anything like that then you just aswell drop the lot and do it all in one go rather than battling to get into tight spaces[/quote
 
Thanks Bob, its all done now and its sitting in front of the car ready to 'pop' back in  I suppose it will be like a new box having a whole bearing kit replaced!!! Ok will do the fork mod then, Rich has had plenty of practise of welding from when I had the Cherry Turbo

Gearbox is back!
 

 
Clutch Fork before the mod:
 

 
Clutch Fork after the mod:
 

 
Going to order the Excedy Clutch tomorrow, Rich has given me money towards that as my Christmas present  Hopefully will be up and running by Christmas!!!

That rich spoils you to much   like the metalic paint on the fork 

nomad wrote:That rich spoils you to much   like the metalic paint on the fork 

 
 
Ha ha!! I am very spoilt!! The finish is very smooth, almost too nice to go back on the car!!!!