He is 100% going to have to remove the gearbox/diff from the car. He will then need to strip the gearbox for which, no doubt, he will need some tools specific to this gearbox. He willneed a parts washer to ensure everything is scrupiously clean and then the rebuild can start. Special tools and a full set of manufacturers data this gearbox are essential.

Add to that several years of experience rebuilding gearboxes and he will be fine.

Judging form the questions i think its fair to say you dont even have a basic manual or any idea how to repair a gearbox so I suggest you leave well alone and accept its going to cost you.

No internet forum can fill the gaps when years of experience is essential.

Consider that very few garages actually rebuild gearboxes, they either send them to specialists or fit a recon unit.

http://clubjazz.org/forum/index.php?topic=4739.msg20218#msg20218

If you feel competent enough to remove the box yourself go head but I urge you to follow the instructions in the manual, whoever wrote it knows a lot more about the Jazz than you do.

I would also urge you to take the box to a gearbox specialist to be rebuilt or simply exchange it for a recon box, gearboxes are NOT a DIY job.

Doing it this way you will save a good wedge of cash.

Whilst the box is out replace the clutch and release bearing, not expensive but whilst its apart easy to do.

The box is out and we have taken it to be sorted professionally. Also ordering a new clutch as you say whilst we're at this stage makes sense to do it now.

Well done the two Wispy's, you've saved a good wedge of cash by doing the donkey work yourselves.

Might be nice when the work is completed to write a short job summary incl approx costings and submit it here and to HJ himself, who will most likely include it in his reviews section above where it will be of good use for others who own these cars....i expect Avant will make sure it gets linked to somewhere too.