Pete Lewis Posted April 3, 2023 Report Share Posted April 3, 2023 if its baulking i suggest the clutch may not be fully clearing check a re bleed , push the piston back in as far as it will goe to reduce cylinder capacity when bleeding it will pump back out witha few pedal strokes when done , and bleed nipple must be uppermost above the feed pipe Pete Link to comment Share on other sites More sharing options...
Jonah Posted April 3, 2023 Author Report Share Posted April 3, 2023 The other three gears can be selected fairly smoothly with not much effort but second requires a really hard pull to select it Julian Link to comment Share on other sites More sharing options...
Jonah Posted April 3, 2023 Author Report Share Posted April 3, 2023 Could this be reacted to the remote, I did overhaul it with a rebuild kit? I’ll look at the clutch now Julian Link to comment Share on other sites More sharing options...
Pete Lewis Posted April 3, 2023 Report Share Posted April 3, 2023 simple test for clutch drag engine idles and its hard to select yes its clutch drag engine off and engages easy yes its clutch drag try it Pete Link to comment Share on other sites More sharing options...
Jonah Posted April 3, 2023 Author Report Share Posted April 3, 2023 It’s the same with engine idling and off Pete Link to comment Share on other sites More sharing options...
Pete Lewis Posted April 3, 2023 Report Share Posted April 3, 2023 (edited) that might mean a look at the detent plunger springs etc and the springs in the 1st/2nd sliding hub sleeve there are different length springs 3/4th to 1/2nd but as 1/2nd has the longest so that mix up doesnt suit do make sure the remote is not fouling up some how its common for the lower bolt to be back to front but that affects 3rd not 2nd how is 1st is that ok as that eliminates the sleeve spring idea did you strip out the top cover and all the shafts and forks ???? Pete Edited April 3, 2023 by Pete Lewis Link to comment Share on other sites More sharing options...
Jonah Posted April 3, 2023 Author Report Share Posted April 3, 2023 1st is ok and selects easily i didnt strip the top cover at all I just rebuilt the floppy remote Julian Link to comment Share on other sites More sharing options...
johny Posted April 3, 2023 Report Share Posted April 3, 2023 With engine off you could try pushing the lever down as if going for reverse but pull it back for second and see if this makes it any easier. Im just wondering if the reverse stop plate is pushing the lever over a little so making it difficult for the selector to enter its slot correctly. If you select second then come out back to neutral is it then easier to go back into second? Link to comment Share on other sites More sharing options...
Jonah Posted April 3, 2023 Author Report Share Posted April 3, 2023 That’s interesting Johny, I’ve taken the remote off and I can see that the reverse adjustment screw was wearing hard against the housing and preventing proper selection of 3rd I’ll adjust the screw now and refit to see if it’s made any difference julian Link to comment Share on other sites More sharing options...
johny Posted April 3, 2023 Report Share Posted April 3, 2023 sounds like a substitute bolt has been used as the real set up should look like this.... Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 Despondent Spitfire Driver after a longer drive this morning none of my adjustments have worked now that it’s warmed up I can’t get second at all even with a lot of grunt also the speedo no longer works! on the upside the overdrive now works well I’m sensing the gearbox will have to be pulled again any thoughts chaps? despondent Julian Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 It might not be that bad and only need the gear lever extension cover removing to see whats happening. Hopefully its the selector not going into the second gear slot but of course not easy to see why once the assembly is lifted off. When you have access the gear change can be operated with a suitably sized bar used instead of the selector and if the resistance is still present you'll have to remove the top cover. Then you should be able operate the actual synchroniser hub with a strong hand (the manual says 8.6 - 9.5kg of load should move it) while watching whats happens to the gears.... Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 Thanks Johny if the selector isn’t going into the second gear slot what could be the cause? Julian Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 It could be bent or something obstructing its correct path. However given the history it does seem likely theres a problem with the gearbox internals and Im not sure if a synchro hub installed incorrectly could explain whats going on... Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 Did you try my suggestion of depressing the lever and wiggling it a bit while selecting second? Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 Yes I tried it but no difference after the test drive I can’t get it into 2nd at all i wondered if it’s the second gear synchro hub causing the problem, the synchro ring itself was completely worn away Julian Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 I can see a worn hub giving poor gear changes but not to completely prevent them however I seem to remember somebody putting one in the wrong way round. Did you dismantle the 1/2 hub to inspect its centering balls and springs inside? Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 When I dismantled the gearbox the synchro hub exploded several times but seemed to go back together ok with all the all bearings and springs After reinstalling I was able to get into second gear before the test drive albeit with a great deal of hard pull from first gear, but now it won’t Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 The outer sleeve went back on the inner hub the right way round? It'll fit perfectly either way but of course when you put the assembled unit back on the shaft the inner is positioned incorrectly. Workshop manual has great section diagram that shows it all.... Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 I can’t really say it was with any accuracy Johny, I assumed it was heres a pic taken with the remote off Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 Heres the 1/2 sychro hub Im talking about. You can see the inner hub where the ball and spring sit isnt symetrical so the outer sliding sleeve can look correct but inside its wrong. In fact once in place its very difficult to verify this. Anyway first things first.... Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 Ahh, If the synchro hub was the problem would it also affect selection of 1st gear Link to comment Share on other sites More sharing options...
johny Posted April 4, 2023 Report Share Posted April 4, 2023 That Im not sure about but I think it has the potential to - we need a gearbox expert please? However first if you put a bar in the centre slot shown in your photo and push it forward you should be engaging 2nd gear.... Link to comment Share on other sites More sharing options...
Jonah Posted April 4, 2023 Author Report Share Posted April 4, 2023 This as far forward as I can push it mid that enough to select second? Link to comment Share on other sites More sharing options...
NonMember Posted April 4, 2023 Report Share Posted April 4, 2023 That looks like a bit under half way in, certainly not properly selected. Try again with the clutch down, in case it's just baulking. If it really won't go beyond there, I think the cover needs to come off. Link to comment Share on other sites More sharing options...
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