Before we get started, here are the tools you’ll need to have on hand to make this run smoothly:
Wrench
Allen key (s)
Flat chisel
Hammer
Pry bar
First, undo the bottom drain plug at the bottom of the gearbox and drain the oil into a pan. Clean it all up and now you’re ready to disassemble.
Next, remove the five bolts that connect the gearbox and pump with the engine. There are four large bolts that face the pump and one medium size bolt at the bottom that faces the engine. Remove these five bolts and separate the two components.
Tip: If you have trouble, this is where the flat chisel and hammer come into play. To get the separation started between the two components, lightly hammer the chisel into the crevice that joins the two components and you’ll have them apart in no time.
Set the engine to the side for a moment as we focus on the gearbox and pump that are still connected. Inside the gearbox you’ll see a gear and three bolts. Remove the three bolts. Then separate the gearbox from the pump. This will allow you to have better access to the pump and/or replace the pump altogether if necessary.
Tip: Use your flat chisel to hold the gear in place while you loosen the bolts.
To separate the other part of the gearbox from the engine, you’ll need to remove the four small bolts that connect the two components. Then you may have to enlist a variety of tactics to separate the two. You could turn the gearbox and using a rubber mallet gently tap the gearbox to loosen it. Another option is to use a pry bar or two to nudge the gearbox off the engine. Worst-case scenario is that you destroy the gearbox in the process and will need to replace the gearbox altogether.
Tip: Cut down a standard allen key that fits this size bolt. Having a shorter allen key will provide easier access to take the top bolts out.
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