Gearbox Swap - Hours / Garage Help please

[Crook]

Hi

I've recently purchased a 7 with the Ford engine to go racing (Sigmax Graduates) which came with a spare rebuilt gearbox. At some point (most likely prior to the start of the season) I know I will need to swap it out. The guys who have done some of the prep work have said it's a 10 hour job (!!!!!) as the engine has to come out and fluid replaced etc.

Whilst I don't doubt their word I also don't doubt that there are other Caterham specialists and even normal independent garages who are quite capable of this job.
Is anyone able to offer any suggestions please?

The car is currently living in Northampton but it isn't afraid of travel.

Many thanks,

[Megaflow]

It is a big job, the engine does have to come out, but 10 hours is a bit strong.

The last one I did, in a Westfield, I think took 5 hours.

Have a chat with Troy at Northampton Motorsport, they know they way around Sevens well.

[Crook]

Many thanks for the swift reply, I'll give them a call.

[bluecob]

Any of the Caterham based specialists will be able to assist and yes it is an engine out job. My sons business www.pgmsussex.com can certainly help but is in West Sussex so probably a bit too far for you. As previously mentioned Troy and his guys are most helpful. Kind regards.

[carphotographer]

I was listening to Simon Lambert today, he's Caterham Chief Motorsport + Technical officer and he says the quickest he's had a gearbox change was 1hr 45mins.
Ten hours sounds excessive , I wonder if the company who quoted that was the same company who quoted my 2 1/2 hours to remove a cage and fit a roll bar ..... took me 30 minutes.

[CharlesElliott]

Is it a race team doing the prep work? I'm surprised they are quoting 10 hours.

[PH User]

Who's quoting 10 hours? It does sound a bit excessive!

[pingu393]

There's a programme on telly "Best of British" (I think). It shows them building a Caterham at the factory. There is a bit where they fit the engine/gearbox. It was a two man job. Second man assisting.

Might be worth a look.

[Crook]

Thanks everyone.
They're quoting 6-8 hours depending on how smoothly.
Crazy idea... if it's just undoing stuff and then doing it back up again, I can't imagine it's that difficult a job with the right tools?
For context have swapped engines / gearboxes / fitted clutches etc. on 80's RWD cars in the past.

Edited by Crook on Thursday 9th December 17:27

Edited by Crook on Thursday 9th December 17:28

[CharlesElliott]

It is engine and box out together, split them, reattach new box and then put both back in.

3.5 hours for two people (=7 hours) is reasonable in my view. I've done it a few times myself!

[PH User]

What garage is it crook?

[Crook]

Quoting 10 hours? I'd rather not say.
But quoting 6-8 is Troy in Northampton.

Good to know on the box/engine out together. I think I'll investigate a bit more on getting hands on.

Thanks again.

[Megaflow]

If you have swapped engines and gearboxes on 1980’s RWD stuff in the past you’ll be absolutely fine.

As others said, easier to take them out as a unit. Normally a bit of a bugger to get back in, due to the tight tunnel.

The advantage with a Seven, is in about 30 mins the bonnet, nose, radiator and fans are off giving as much access as you could ever need.

[Crook]

Megaflow said:

If you have swapped engines and gearboxes on 1980’s RWD stuff in the past you’ll be absolutely fine.

As others said, easier to take them out as a unit. Normally a bit of a bugger to get back in, due to the tight tunnel.

The advantage with a Seven, is in about 30 mins the bonnet, nose, radiator and fans are off giving as much access as you could ever need.

[Paynewright]

Two of us yesterday (at leisurely pace with multiple tea breaks and lunch) pulled a largely disconnected engine & box from a seven, changed the clutch and put it back in again between 1000 & 1500 (so prob 3 hours actual effort). Bear in mind car was stripped of rad, exhaust, elec connections & fuel lines prior to starting and this all needed re-connecting when I left. Despite trying to seal the gearbox tail we got gear oil everywhere (no drain plug) which took a while to mop up!

I think 6-8 hours is reasonable for a professional!

[BryanC]

Bit late now but was told a rubber glove fitted over the end of the gearbox is a good hack to stop oil loss.

[Paynewright]

BryanC

I’ll remember for next time - the 4 speed sport box has the selector housing and output shaft cast in one piece so difficult to get anything around it. A bung would be best!

Cheers

[Boggo]

Do engine and box separately next time - it's how most of the teams do it at the circuit, and makes the whole process a lot faster as there is no messing with leaning the engine back and the gearbox mount's go in a lot easier (so do the engine mounts!)

[Crook]

Boggo said:

Do engine and box separately next time - it's how most of the teams do it at the circuit, and makes the whole process a lot faster as there is no messing with leaning the engine back and the gearbox mount's go in a lot easier (so do the engine mounts!)

Can you explain what you mean please? are you talking about splitting the box off before you remove the engine?

Thanks

[CharlesElliott]

Crook said:

Boggo said:

Do engine and box separately next time - it's how most of the teams do it at the circuit, and makes the whole process a lot faster as there is no messing with leaning the engine back and the gearbox mount's go in a lot easier (so do the engine mounts!)

Can you explain what you mean please? are you talking about splitting the box off before you remove the engine?

Thanks

Yes, you can do this. Undo the bell housing to engine bolts and lift the engine out on its own. In my view, if you need to take the gearbox out, then it's a bit quicker to do them together but not much in it. If the gearbox doesn't need to come out, I would split them.