Joanna K Posted October 24, 2021 Author Report Share Posted October 24, 2021 23 minutes ago, johny said: What did the laygear bearing surfaces look like Joanna? They usually last better than the layshaft but if this is the boxes second rebuild might now have worn through the case hardening meaning that the wear rate accelerates😢 Hi Johny, it has some wear on one end in the bearing surface. I’ve installed the new bearings and temporarily installed the layshaft and spinning the cluster on it I can feel no roughness 1 Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 24, 2021 Report Share Posted October 24, 2021 with any gearbox there is utopia and compromise it all depends on how hard you want to drive it and are you driving to scotland evert week or tootling to area event some wear you can get away with but some needs replacing a new cluster is very expensive so its a balance act of usage and ££s the mainshaft and lay spindle will make a big improvement it may not be as good as new thats more finicky and costly pete 1 Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 25, 2021 Report Share Posted October 25, 2021 thanks for message will post picture here its easier than on the message system this shows a good deal of rotational wear but its really quite usable and better than the pic suggests Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 26, 2021 Report Share Posted October 26, 2021 used part posted , wait to see if it gets used Pete Link to comment Share on other sites More sharing options...
Joanna K Posted October 30, 2021 Author Report Share Posted October 30, 2021 Saturday, between the rain showers, fun. New clutch and backplate 1 Link to comment Share on other sites More sharing options...
johny Posted October 30, 2021 Report Share Posted October 30, 2021 Nice feeling knowing that the clutch is new and not going to need doing for a long time! Is that an alloy backplate? If so extra easy does it when the box goes back in... Also have you checked the bronze input shaft support bush in the crank for wear? 1 Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 30, 2021 Report Share Posted October 30, 2021 and if the new throwout bearing is a thin 16mm you need to add a washer under the clutch Hsg pivot post its a light push fit in the alloy hsg. the bearing should be 19mm thick moving the post out a little corrects the angle of the arm its a common problem ) theres a recent post with a lot of this discussed on a 1600 ( it applies to all 6 cyls ) Pete Link to comment Share on other sites More sharing options...
Joanna K Posted October 30, 2021 Author Report Share Posted October 30, 2021 41 minutes ago, johny said: Nice feeling knowing that the clutch is new and not going to need doing for a long time! Is that an alloy backplate? If so extra easy does it when the box goes back in... Also have you checked the bronze input shaft support bush in the crank for wear? Johny, yes it is aluminium. And no, I haven’t checked it yet, I mean - I haven’t thought of it. Thanks for the heads up Link to comment Share on other sites More sharing options...
johny Posted October 30, 2021 Report Share Posted October 30, 2021 According to the manual limits of clearance shaft to bush are 8.5 to 5.8 thou. Hard to measure but definitely not a close fit.... Link to comment Share on other sites More sharing options...
Pete Lewis Posted October 31, 2021 Report Share Posted October 31, 2021 why not use the stem gear from the stripped box to check for any nasty waggle in the spigot bush ??? Pete Link to comment Share on other sites More sharing options...
Joanna K Posted October 31, 2021 Author Report Share Posted October 31, 2021 2 hours ago, Pete Lewis said: why not use the stem gear from the stripped box to check for any nasty waggle in the spigot bush ??? Pete All seems good in this area. PS- I made slow progress on the mainshaft assembly this week. I found all springs from both gear hubs to be broken. Waiting for a delivery from Canleys Link to comment Share on other sites More sharing options...
johny Posted November 1, 2021 Report Share Posted November 1, 2021 I dont know about accidentally, youve got to open up each hub to check the springs as part of any rebuild havent you? Ive found broken ones before and its definitely best done inside a plastic bag! Link to comment Share on other sites More sharing options...
Joanna K Posted November 1, 2021 Author Report Share Posted November 1, 2021 I had to use a magnet to take mine out 😅 Link to comment Share on other sites More sharing options...
Pete Lewis Posted November 1, 2021 Report Share Posted November 1, 2021 and whilst the springs look very similar the 3/4th hub are different to 1/2nd in their lengths on refit slide sleeve down and prod each ball with a screwdriver blade just enough to let the sleeve start to hold it when all 3 are in place push sleeve fully down you cuold wire the sleeve in place to stop things flying apart on rebuild as for reassy i always do this vertically i use an old stem gear in a vice ( a wooden with hole for mainshaft tip works) and drop the whole case / cluster and mainshaft onto the support you can then knock the bearing down the shaft and into the case the advantage of this seemingly daft clue is gravity stops the two collet thrusts on 2nd continually jumping out as the gears jump when you tap the bearing on yes its a bit heavy and unweildy but this works and saves repeated cursing always take care with the 3rd gear circlip you dont want to over spread this on refit easily done needs to be a good tight fit as they can decide to pop off if slack have fun Pete Link to comment Share on other sites More sharing options...
Joanna K Posted November 2, 2021 Author Report Share Posted November 2, 2021 1 hour ago, Mathew said: This is the tool for holding the mainshaft in place while i press the bearing in. I’ve never seen one like this before Link to comment Share on other sites More sharing options...
Pete Lewis Posted November 3, 2021 Report Share Posted November 3, 2021 hence use old input shaft or make a support out of hard wood another thought is use /fit the exisiting input shaft a bearing use that as a mainshaft support drop the whole assy over and into once in place tap the bearing down the shaft and into the case then revert to upright and raise the cluster with your wire/string loop , pop the new shaft in place keep an eye on thrust washers in fact a short bit of dummy (anything) shaft to locate the thrusts can work popped in each end of the spindle bore to hold the thrusts in place Pete Link to comment Share on other sites More sharing options...
Joanna K Posted November 3, 2021 Author Report Share Posted November 3, 2021 1 hour ago, Mathew said: In practice i never found the main bearings hard to put in place, held in position by the ring and covers both sides. That’s my job for tonight! Almost there, almost there… Link to comment Share on other sites More sharing options...
Pete Lewis Posted November 3, 2021 Report Share Posted November 3, 2021 let us know how many times the thrust collets jump out then up end it ha Pete Link to comment Share on other sites More sharing options...
Pete Lewis Posted November 3, 2021 Report Share Posted November 3, 2021 when we rebuilt PaulH's box last month the rear bearing was a right tight pig to fit tight down shaft and in case a lot of whacking with the coal hammer well you know what i mean Pete Link to comment Share on other sites More sharing options...
Pete Lewis Posted November 3, 2021 Report Share Posted November 3, 2021 having a press ........... not all have the luxury many have a variety of ....hammers agree you need extra pair of hands is very useful on your own its a bit of a acrobatic rules apply or them split thrust's are ........... out again ...........and again or they're are out and you dont realise ....what you mean end float !! Pete Link to comment Share on other sites More sharing options...
Joanna K Posted November 3, 2021 Author Report Share Posted November 3, 2021 Any other possible things that could go wrong tonight guys? 😜 Link to comment Share on other sites More sharing options...
johny Posted November 3, 2021 Report Share Posted November 3, 2021 The worst thing is not knowing youve done it right until its back in the car and you drive it! Ive wondered if a beefy electric drill couldnt be used to power the rear coupling on the bench and then go through the gears - should test the synchros and better than nothing? Link to comment Share on other sites More sharing options...
Joanna K Posted November 3, 2021 Author Report Share Posted November 3, 2021 1 hour ago, johny said: The worst thing is not knowing youve done it right until its back in the car and you drive it! Ive wondered if a beefy electric drill couldnt be used to power the rear coupling on the bench and then go through the gears - should test the synchros and better than nothing? Johny, that’s the worst thing…hopefully I will be able to check it this weekend. I took thousands of photos to document the whole process, so it wasn’t difficult to put it all back together. Unless, I skipped a photo at some point 😂 Link to comment Share on other sites More sharing options...
Pete Lewis Posted November 4, 2021 Report Share Posted November 4, 2021 you need something pretty powerfull to drive the box being involved with gearbox test beds in the factory and solving synchro problems its not a feasible diy job just compare what whacking big drill speed you can get with clutch and propshaft revs and power if the dog teeth and sleeve have well defines chamfered teeth the baulk ring doesnt bottom out and wrings onto the cones firmly by hand and you get a half tooth rock over between sleeve /ring/ dog teeth it will work Link to comment Share on other sites More sharing options...
johny Posted November 4, 2021 Report Share Posted November 4, 2021 hmmm most powerful 240v drill I can find is 1500w so around 2hp to turn the 3 shafts of a small chassis gearbox? It might work but the drill motor probably wouldnt last very long due to overheating - I'll report back when I do it one day😲 Link to comment Share on other sites More sharing options...
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