Major update on my 2000 Maruti 800: New mounts, clutch & gearbox bits

I decided not to give it to any workshop, instead overhaul and clean the stuff perfectly at home. Parts collection took nearly 3 months as most of them came from Japan.

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Part 1: Gearbox: I was offlate facing some issues like

• Gearshifts becoming hard when AC compressor kicked in. This was eventually traced to a broken gearbox mount.
• Gearshifts weren't as butter smooth as they used to
• This got worsened if the car was driven for long. Gearshifts became progressively harder as temperature went up. Clear case of bad pressure plate.
• There was a mild release bearing sound coming too.

This was surprising because clutch was fairly new and wasn't used much. I also came to know that Maruti is doing silent recalls of release bearings as some batches had issues.

My 800 originally came with Exedy Clutch(3 spring design) and NTN Japan release bearings. That feel never came with MGP parts. Hence I decided to get parts from Japan. Also we decided to comprehensively check the gearbox as it was being lowered. I decided not to give it to any workshop, instead overhaul and clean the stuff perfectly at home. Parts collection took nearly 3 months as most of them came from Japan. Also some parts were discontinued long time ago, and were tough to find.

Subsequently, we replaced the following

• Engine Member
• All Engine & Gearbox mounts and cushions
• Gearshift link rods and associated bushes
• All Needle bearings of gearbox
• All Oil seals of Gearbox
• All Synchroniser rings, two of them were worn out
• Clutch Set and Release bearing
• Speedo Drive gear
• Gear Oil

The removal and disassembly part was fairly easy and I could manage it almost myself with a bit of help from dad. But for assembly, I took help of Arjun and his associate.

Cleaning and careful analysis of each part took most of the time. I guess we spent nearly a week for gearbox overhaul.

Some pics:

-Exedy Clutch Set from Japan:

-Shifter

-Synchros and bearings from Japan:

-75W90 GL4 Total Gear Oil:

-Collection of parts:

-New Engine Member:

-SGP NTN Make release bearing:

-Gear lever mount, notice the quality difference between MGP and SGP:

-New Flywheel, however we didn't change it later. Kept it for future use as this has been long discontinued:

-Parts disassembly begins:

-New vs Old Clutch:

-Speedometer Gear:

-Used this Jugaad to hold engine in place while the engine member was being replaced. Must say, this was the most risky moment, glad we pulled it off!

-New vs Old member: The old member had changed in dimensions significantly, thanks to engine load:

-I then started cleaning the gearbox comprehensively.

-Bought this bearing remover toolkit, instead of hammering to remove things:

-Arjun and his associate assembling back things:

Also used this opportunity to change engine oil and oil filter. As usual, used Shell Helix Ultra 5W40.

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