Ok so after an eventful ending to April the gearbox decided to go bang on the Leon and the clutch is shafted!
So I started removing the gearbox the weekend before last (26th April) and thought I'd take a peek inside...
And lastly, the clutch! Or at least what is left of it...
So my decision at this point was what to do next... I've always wanted to do the 4WD conversion on my Leon with the quattro/haldex rear etc! So that was my choice, on Friday evening last week I went to pick up an Audi A3 1.8t Quattro and then Saturday I started removing the front end and the gearbox, engine etc and then started to put the gearbox on my Leon
The transfer box was a pain as it was hitting the back of the engine when trying to get the gearbox into place, in the end I dropped the subframe so I could lift it up into place a lot easier, it was still a nightmare to get into place but none the less we got the gearbox in!
Sunday morning I started finishing off bits and pieces, putting the rest of the bolts in the gearbox and tightening them up and putting the starter motor back on etc, got the passenger driveshaft back in and the leg on all bolted p and back on its wheel that side
Now the fun began! On the drivers side obviously I needed to use the A3 quattro driveshaft as it is shorter due to the transfer box... But turns out the oil return line from the bottom of the turbo to the sump is in a different position on the Quattro, it's a longer pipe and goes towards the side of the engine before round to the turbo! So my original line was right in the way of putting the driveshaft on! I had the oil line I needed as I had the engine off the A3 still, but it was a complete pain in the ass to get the line off as it was very tight between the bottom of the turbo and the transfer box. Had I known about this before putting the gearbox on it would of been a 2 minute job
Anyway I got the old one off but struggled like hell! So I decided to drop off the transfer box to put the new one on, got that all tightened up and on and then the transfer box was back on and the car was good to go again! (After bleeding the clutch obviously)
Then I had oil dripping like mad
so I thought I hadn't tightened up the oil line properly or something as it was dripping when it was running but I couldn't get to it to check it was tight etc, so I ordered a new gasket and 2 new bolts for the oil return line... Then got at it lastnight and dropped the transfer box back off and then removed the line and put the new bolts and gasket on and sealed it all up
I now know why it was leaking!! The bolts I had put in were wrong, well one of them was. I had one bolt longer than the other and the long one was obviously hitting the end of the hole/thread before tighening the oil line to the turbo! But anyway this is all done now and part 1 of my 4WD conversion is complete, it now has the 4WD gearbox and transfer box.
The Leon is now usable for time being, I'm giving myself a couple of weeks to get the A3 stripped down of all parts so that I can start drilling the spot welds out and cutting the floor out ready for it all to go on to the Leon