Replacement DMF and Gearbox overhall

[Butt0ns]

Got my Biturbo booked into a specialist gearbox repair guy on Wednesday to replace flywheel, friction plate, pressure plate, release bearing and hydraulic cylinder plus split gearbox for a check and replace any worn bearings. I'm getting a bit of 3rd gear movement of the gearstick under hard acceleration/lift off. Plus there's a little whine in 2,3,4,5 (mainly in 3,4 but audible in 2 and 5 too) only at certain speeds and only on trailing/neutral throttle, but that may be due to normal wear. Its hard to pick up the noise but I'm a dick with this stuff. I initially thought it was inner CV joint (which has play in it) but this may be the problem since I noticed the bit of movement in the gear stick which indicates a problem with one of the 3/4/R end shaft bearings. Anyway this guy knows his stuff so should be sorted by friday. I do 50-60kms per year so I need to get this sorted. Of course the 'service suspension system' warning came on today too, another wire gone on the rear axle - had one go about 2 months ago! I hope.

[Butt0ns]

Note to self: when one wire of a pair breaks, replace BOTH of them, dont just change one as you'll end up changing the other one soon. Second wire gone on offside rear loom.
Should have her back by tomorrow afternoon. R/3/4 shaft bearings being replaced, small amount of wear. Theres some pin in the differential which can come loose and destroy the gearbox, thats been changed so it cant happen. He had one in the shop with a 4" hole in it. Clutch was a Sachs. There was a lot of wear on the flywheel. I'll have pictures tomorrow or sat.

[0011728]

Wow, alot of work. Expensive?

[Butt0ns]

Grand total including parts and labor, ......drum roll......
€1500 which is about £1,335
Its a lot of money but the flywheel had to be done and I wanted to be sure the gearbox wasnt going to give any trouble any time soon, with the movement in the gear lever which based on the M32 had me worried. I don't think that's too bad as I was originally quoted €2400 (£2135) by Opel to replace the flywheel only. This would be reduced to €1600 (£1425) using the service club gimmick. My local independent quoted €1000 (£890) again for flywheel only, he wouldnt do the gearbox.
All parts were replaced like for like with original Sachs parts, Flywheel (need to clean to have a look for part no.), clutch disc (GM55571806) and friction disc (GM55562132) and FTE release bearing. The 2 main shaft bearings on 3/4/R were replaced and shimmed to remove the bit of endfloat on the shaft. There was a lot of play between the 2 halves of the flywheel i.e. not rotational but wobble. You can separate the 2 halves by about 2/3mm and wobble it about. This I assume was causing the vibration, which is now gone. I never heard of any pins coming out of the diff but he says it can happen esp on high milers, of which I am.
Anyway money now spent, next thing is inner CV joint which I seriously thought about replacing with this work but couldn't track one down in time, or timing belt in about 9 months time. Or the flaming shocks will go, or another glow plug. Or something else!
I'll get a few pics tomorrow of used parts.
The 3/4/R main shaft bearings were not pitted or anything and I probably would have got away without splitting the box, but you never know.
Anyone want a BiTurbo!

[Butt0ns]

Oh yeah the rad leaks too, only a tiny amount - top up every 3/4 months