Andrew Palmer Posted September 8, 2019 Report Share Posted September 8, 2019 Hello everyone. I need to replace my gearbox top cover (because the threads are stripped in the stud holes and I can't torque down the gear lever remote housing). So, I've got a used top cover and I'm about to transfer the gear selector shafts/selectors across. Only, I've just noticed that the 'new' top cover is missing the side plug that seals off the selector shaft interlock hole (part 107099). None of the usual suppliers have this plug, and the one in my old top cover is completely stuck! Any ideas on how to get it out?! Cheers. Andrew Link to comment Share on other sites More sharing options...
Pete Lewis Posted September 9, 2019 Report Share Posted September 9, 2019 Its not really removable sort of pressed in for life I would tap a thread in the replacement and cap with a short setscrew If thats an idea Pete Link to comment Share on other sites More sharing options...
johny Posted September 9, 2019 Report Share Posted September 9, 2019 As an aside, whats in there and what does it do? Link to comment Share on other sites More sharing options...
Clive Posted September 9, 2019 Report Share Posted September 9, 2019 another aside... Any reason you didn't just helicoil the stripped threads? may well be the easier way forward. Link to comment Share on other sites More sharing options...
Pete Lewis Posted September 9, 2019 Report Share Posted September 9, 2019 the bore is to house the balls and pins that interlock between the 3 selector shafts to stop getting more than one gear at a time theres two balls between each shaft and a pin thro the centre shaft these drop into grooves in the shaft so when one is selected the balls lock into the other grooves and stop and shaft movement Pete Link to comment Share on other sites More sharing options...
johny Posted September 9, 2019 Report Share Posted September 9, 2019 Thanks Pete, I see them now. Are there any springs involved or is it just all done by positioning? Link to comment Share on other sites More sharing options...
Pete Lewis Posted September 9, 2019 Report Share Posted September 9, 2019 no spring ..........just get the balls in the right place the groove is like a detent about half a ball deep as the shaft moves a plain section fwd. the ball sits in the opposing shafts detent and locks it i was going to say dimples but that invokes drift . Pete Link to comment Share on other sites More sharing options...
Andrew Palmer Posted September 10, 2019 Author Report Share Posted September 10, 2019 On 09/09/2019 at 08:57, clive said: another aside... Any reason you didn't just helicoil the stripped threads? may well be the easier way forward. Thanks all. Clive, I've never done the helicoil thing and don't have the gear. Do you reckon it woudl be easier than Pete's suggestion? ... if so, can you recommend a kit? Thanks. Link to comment Share on other sites More sharing options...
Pete Lewis Posted September 10, 2019 Report Share Posted September 10, 2019 these are the 4 studs in the top cover ?? you could tap them 8mm x 1.25 nd see how that goes they dont locate ,theres two dowels that accurately position the remote and use 4 setscrews rather than studs .. pete Link to comment Share on other sites More sharing options...
Andrew Palmer Posted September 10, 2019 Author Report Share Posted September 10, 2019 Thanks Pete! Link to comment Share on other sites More sharing options...
Pete Lewis Posted September 10, 2019 Report Share Posted September 10, 2019 8mm is similar to the 5/16" but coarser thread may just give enough bite to reclaim . just dont tell the rivet counters its no unified dont gorilla the fixings a nice nip is all thats required helicoils are available from places like machine mart and screwfix you have a tap to open the thread and the insert sprals to make the same pich and diameter as the original often used in alloy repairs , but if you dont need it very often they are a few ££ eg https://www.screwfix.com/p/helicoil-eco-thread-repair-kit-m6-x-1-0mm-14-pieces/293fr#_=p Link to comment Share on other sites More sharing options...
Andrew Palmer Posted September 10, 2019 Author Report Share Posted September 10, 2019 That's great thanks Pete. I take what you say about the torque - the threads were a bit dodgy and then I mullered them by overdoing it. Think I read the wrong line in the list of torques in the Haynes manual! Link to comment Share on other sites More sharing options...
Andrew Palmer Posted September 10, 2019 Author Report Share Posted September 10, 2019 Last question! ... would it be even better to get this UNF kit?? https://www.workshopping.co.uk/product/helicoil-type-unf-thread-repair-kit-5/16unf-x-24tpi-with-15-d-thread-inserts/VCOILK5-16UNF/ Link to comment Share on other sites More sharing options...
Pete Lewis Posted September 10, 2019 Report Share Posted September 10, 2019 They are all about the same Most fingers and spanner size give the right feel, dont need torque specs on , any normal fixings Engine bearings and cyl head wheel nuts etc need a spec others , just tight not gorilla fists. Pete Link to comment Share on other sites More sharing options...
Clive Posted September 10, 2019 Report Share Posted September 10, 2019 I have bought cheapish helicoil kits of fleabay. Never been an issue in use, and good enough for the infrequent use they get. EG this kit from Rally Design (very decent company) https://www.ebay.co.uk/itm/5-16-UNF-Helicoil-Thread-Repair-Kit-Race-Rally-Design/321677426253?hash=item4ae577fe4d:g:hSAAAOSwSutaGDGx Link to comment Share on other sites More sharing options...
Colin Lindsay Posted September 11, 2019 Report Share Posted September 11, 2019 I think the Helicoil kits are all more or less the same. I bought this one in UNC for the TR7, and after the initial expense just bought more inserts in the required size depending on the car I was working on, whether metric or UNF. Easy to use and works a treat. https://www.ebay.co.uk/itm/V-Coil-5-16-UNC-Wire-Insert-Thread-Repair-Kit-Fits-Helicoil-04108/281957230747?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649 Link to comment Share on other sites More sharing options...
Andrew Palmer Posted September 11, 2019 Author Report Share Posted September 11, 2019 Thanks everyone! Link to comment Share on other sites More sharing options...
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