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TOYOTA AYGO GEARBOX / CLUTCH REPLACEMENT, Same as Citroen c1 and Peugeot 107
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hey you guys got a problem gear change
from first to second it's really stiff
you started when you were changing down
the gears second into first
it just wasn't spinning the Box up and
just wouldn't go into first from second
that's been happening for a little while
but it began slowly worse and now like I
say first a second completely gone as
well even with the engine off it just
doesn't want to go first
secondly just it's just jamming so goes
third fourth fifth first don't want to
go in second don't want to go in so time
for new gearbox managed to pick one up
let's whip this one out stick a new one
in so we've got to clear a bit of room
out yeah batteries got to come out
battery carrier and whip some of the
bolts out on top we'll start by just
disconnecting the battery whip them turn
those off to ten mill nuts then we're
going to disconnect the battery
retaining carrier a little twelve
millimeter nut at the front with the
so I'm just pulling the retaining clip
off the cable and pulling the cable away
and then doing the same with the other
one to remove both their selector cables
yeah bingo now we're going to remove the
two 12 mil bolts holding the gear
selector to the job bartending me finger
lock and it's a it's a bit of a gusher
dough it's just starting to slow down a
bit I'm going to superglue the top of my finger
now we've got the clutch cable it's just
attached so on the same bracket just a
12 mil bolt holding the bracket and then
just pop the connector then down the
front we've got the earth strap and it's
little retaining clamps so just whip
them off now I can crack these
bellhousing bolts off on the top and
then the 14 millimeter starter motor top
bolt and then we've got two more 17 mil
bellhousing bolts one at the front at
the top and then two down the front near
the front of the car now I can just
remove the gearbox mounting bolts
leaving just one to hold in place while
I take the rest of the bell housing
bolts out from underneath here let's
Jack this a go I'll pump up that a go
it's quite clean the oil change at some
point you got to wipe it off not drip it
on yet okay next step I feel I want to
get this oxygen sensor out of the way
cuz I'm gonna catch that when I'm
getting this gearbox out I just I got
failing so I'm gonna whip that out just
to make sure I don't bash it I'll get
this bottom mounting off then we'll pop
the legs off a couple back sourced
Amazon doubt shafts out to the bottom I
get this optional sensor out the exhaust
jigglin know things about so I'm not
quite out for better get this out on the
pit without so many problems let's give
that's the house away we don't want to
break that
that's one less bit often it swing you
need to figure a way of supporting this
engine when I drop this gear box
mounting off so I'm gonna meet something
yeah to to support it right let's get
she's 19 millimeters big birther in
there hate these reverse arms that are
pain are nearly smashed me phone need a
we'll turn the steering forelock so it
gives me a lot more leverage just watch
- hammering between mom and the hook
there just to push that driveshaft out
get it out me why so that's all three
outside well we've got left as a starter
motor at the back and a bulb to the back
and then obviously the mountain and
we've got to just support this engine so
that we don't lose it we don't have to
so I've got an old white bar but a bit
of wood would have done it on the other
end of that and hoof it would just
support this engine when I drop it okay
bars in supporting that shouldn't go too
far now when I dropped the top mounting
off the gearbox and bring it down okay
so we've got left now is - we've got the
bottom starter motor bolt or 14 mil and
we've got this one at the back which is
a 17 mil bellhousing bolts I just
whipped that out now we've got about 14 milks
milks
only 14 mil not that on there huh that's
a little skunk way dog bark you see now
the box is decidedly separating from the
from the engine so we're definitely just
hanging now she's hanging hanging in there
there
right so we're almost ready to lower
lower onto the bar take that top
wants to come out now view from the
other side got the jack with the bar
rested on the bottom of the engine
because I just can't put a jack and down
the pit there it's just not good it's
gonna be in the way it's not gonna be
safe so I think this looks a lot more
secure and we've now going to just
finalize removing the last mounting bolt
here on the gearbox and it's how far she drops
in the bank Wow there we have it gearbox
is out yeah so we left with a clutch
push point if you want to take this off
we just whip these 13 to 12 mil bolts
from outside and take the plate off
we're not going that far in this one
though we're just going to pop the debit
gearbox in and jobs are good in
fantastic ok so we've got the new
gearbox and very nice it is - all nice
and clean so and also the bearing is
beautiful which is one thing that we
were a bit worried about so where I've
greased the splice has put a little
smear of grease on there and just
checked it over everything's as it
should be let's stick it in so the
clutch hasn't got a problem with it but
I can still see without taking the plate
off I can see if it's worn or not let me
so here we have the clutch plate now if
it was replacing it I'll take off these
twelve mill bolts around the outside
take the plate off stick a new one on
but we've got to put the centralization
you put a pin down the middle or
something to make sure that that is
exactly in the center though I should
never get a gearbox back in so this
one's on there to check this over I can
see all these Forks more on where the
the bearing rubs against it and then now
there okay there's not a lot of wear
there now the actual plate itself is
trapped between the two here you can see
if I look between the gap I can actually
see the clutch plate itself and I can
still see on the inner edge and the
outer edge the lines which are marked
into the plate itself and as long as I
can see those lines it's not worn down
to the rivets so it's still got quite a
bit of life left in it so I want to
leave that alone okay everything's
pretty much out of the way let's get
this new box in not my favorite but it's
always lifting
[Applause]
Oh No bash my head we're dead wound
superglue again get the bolt in the back
of the bell housing then we've got one
front one back nice to get this mounting
all sort of roughly about where it
should be yes here we go
okay so now the engines bolt it up I can
get rid of my makeshift engine stay give
us some more room Andre hey again again
right oh that looks like by now that's
looking really good so the starter motor
bolt and the back bolt we was going to
that's the back bolt there and the
starter motor is that the back bear it's
really hard to show you how misses a lot
of this is done through feel rather than
not to look into well here you go
that's the that's the back bolt for the
gearbox and then starter motor top and
bottom one bottom bolt in that and the
other one is from the top so this from
that's a bit of Lube on that goes up
and that's get this exhaust oxygen
connected back up Josh F time okay so
I've got to pull the bottom arm down to
then slice that back in again so I'm
gonna go on sweet recess on there to
well that was easy no no that was beautiful
bingo beautiful chefs are in just got to
get these horrible bottom joints in so
we're gonna have to Jack the hop-up
again pulled it on down and trying to go
she ate him into the bottom arms and
support joints let's give it a go oh god
these things are all quit do you pick
cars back in there she is
bingo
right let's have a look okay what we've
got we've got to get the other starter I
to bolt in which is that one I've got
some more bellhousing bolts to go in so
now we've got the say again the gear
selector mounting bolts such assembly
all in place with the gear selector arms
so now I've just got these arms to go on
and a clutch cable to go back in push
cable is lovely so let's go without
first that feels quite tight there's any
free planer and that's all gonna be down
to that no bearing that was in there
it's a better bearing than the old one
I've got a little bit of free play there
now so I'm hoping that's gonna be about
right let's put a spring back on adjust
it up a bit more finito that's good no I
skate gear selector cables back in the
bottom one slip that on that's right Chuck
okay you selected on first like cable
plug to the back on HS bellhousing bolts
in all the way around some nice and
tight cigar tonight a boxer in touches
or bucking gear selectors are on this
wire back down again battery carrier
back in so let's change the oil in this
gearbox get it all nice and nice and
fresh that's the stuff
so it's a driveline 7580 MV manual
transmission fluid 1.75 liters to the a
go let's go for it to get it out drain
plug 24 millimeter sub kit it might not
be a lot in this long to say this so I
don't know what's in here if there's
okay not a lot though not a lot in there
which I wasn't expecting a great though
because they usually drain these before
they ship for now let's put the plug
I'd say the filler plug on the AYGO is
right at the front and it's this one
just here right on the front so you got
your knock bong wash up so keep them
safe you could put a tube from the top
and do it that way okay so I've got the
bingo I've got it this time that's up to
speed just where we want him
great stuff so the levels now to the the
Bonnie started to run out so we know
we're good we can put this bum back in
dip it up let's get up got bright okay
so let's get the wheels back on and
some really pleased with that I'm just
gonna have one last look round much
we've got no way of leaking out from the
drive shaft seals some bones and stuff
but yeah it's driving really nice
there's no whining there's the gear
selections beautiful super job nothing
coming out and no leaks
happy days there you go one hundred and
fifty seven thousand miles that gearbox
didn't there too bad she lives to fight
another day thanks for watching if
you've enjoyed it it's been out for
please like and subscribe thanks for watching
watching [Music]
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