Iain's 20XE Trackday Nova

Hammer and punch started rounding a tooth off, felt like it was going to break it before it moved. Is the proper tool just called a 'castle nut removal tool', cos I can't find one?

no sure where you would get one from, or what it would be called tbh

make sure you mark it so it goes back in the same place, and count the amount of turns coming out

Flat piece of steel to fit in the "slots" ?

Will have a go but it seems quite tight. Was going to count turns but imagine the figure will be useless as I have a Quaife diff to go in, so will it need tightening specifically for that again?

Stripped down the old damaged box:

http://iainel.co.uk/images/forums/NovaWIP2a/008.JPG

Internals side by side. Both read different part numbers (left is 90 446 357 & 8415-12, right is 90 142 566 & 8415-8), does this mean they're geared differently?

http://iainel.co.uk/images/forums/NovaWIP2a/009.JPG

The internals I want to use have play in this part that enters the box - is this a problem? The other set doesn't have any play at all...

http://iainel.co.uk/images/forums/NovaWIP2a/010.JPG

Can someone maybe do me a how-to to swap over that one broken bit? Is that possible?

Still need a guide on how to change the broken bit over if anyone is knowledgeable on the matter?

Got the diff bearing thinggies out using a big piece of angle iron. Took 5.5 full rotations to come out - can I re-use this setting when refitting my new diff?

http://iainel.co.uk/images/forums/NovaWIP2a/011.JPG

And out comes the diff:

http://iainel.co.uk/images/forums/NovaWIP2a/012.JPG

Cleaned the gears and inspected them all, none seem to be broken:

http://iainel.co.uk/images/forums/NovaWIP2a/013.JPG

Which was a relief, as I found the broken bit. For info, there's a magnet to pick up metal filings/broken bits inside the housing at the bottom!

http://iainel.co.uk/images/forums/NovaWIP2a/014.JPG

Interesting read Iain, i would want to figure out what/how that bit got broken off tough my self, as it seams quite odd!

And as Paul said on the grill, i did it to mine.

Scott

You need to clean your fingernails Ian :p

Thanks Pul.

To speed things along I'm bypassing the oil cooler for now as it can be added at a later date. To do this you need one of these, found on most 8v and ecotec Vauxhalls:

http://iainel.co.uk/images/forums/NovaWIP2a/015.JPG

Bolts straight in ready for the filter:

http://iainel.co.uk/images/forums/NovaWIP2a/016.JPG

Whipped off my clutch bearing, just undo one bolt:

http://iainel.co.uk/images/forums/NovaWIP2a/017.JPG

And off it comes. Assume it's those three bolts behind it to remove the input shaft seal? As I think the kit I've ordered comes with a new one: http://www.transmission-rebuild-kits...l?cPath=90_132

http://iainel.co.uk/images/forums/NovaWIP2a/018.JPG

Box is all clean and treated ready for building back up:

http://iainel.co.uk/images/forums/NovaWIP2a/019.JPG

And FYI the bare F20 casing (with clutch arm thinggy though) is 9kg.

Painting it?

Nah. I've gone over it with Autoglym metal polish to protect it a bit.