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| #Post#: 89445-------------------------------------------------- | |
| Sam's Gearbox Overhaul | |
| By: samc88 Date: June 13, 2014, 4:31 pm | |
| --------------------------------------------------------- | |
| Right then, as you may know, my series 3 has problems with 2nd | |
| gear. I picked up a new (second hand) gearbox from selwyn at the | |
| excellent Bryn Glas Garage in Bryngwran. Picked it up from under | |
| some brambles and theres a plate on the bellhousing which shows | |
| it to be a factory recon unit (hard to make it out but it reads | |
| " The Rover Co. Ltd, Factory Rebuild" ) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130013.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130014.jpg.html][IMG]http://… | |
| This is the only serial number I've found on it, on the side of | |
| the main case, "5766588A", does this make it a suffix A box? | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130015.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130016.jpg.html][IMG]http://… | |
| First task is to remove the gearlever. | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130018.jpg.html][IMG]http://… | |
| This I did by first removing the 2 larger bolts at the rear | |
| using a 15mm spanner (the gearbox I know should be whitworth but | |
| found a 15mm spanner to fit perfectly) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130017.jpg.html][IMG]http://… | |
| I then removed the shorter bolt at the front using an 11mm | |
| spanner. (there should be 2 bolts but only one was present) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130021.jpg.html][IMG]http://… | |
| The bolts holding the main gear lever in place | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130022.jpg.html][IMG]http://… | |
| The 2 smaller bolts also hold down this plate in the bellhousing | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130023.jpg.html][IMG]http://… | |
| As soon as it is removed, I like to put the bolts back where | |
| they came from to avoid losing them and so I dont get confused | |
| as to what goes where | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130024.jpg.html][IMG]http://… | |
| The whole gear lever assembly can be pulled off | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130026.jpg.html][IMG]http://… | |
| The selectors | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130028.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130029.jpg.html][IMG]http://… | |
| Next job is to remove the Bell housing, before this can be done | |
| however, the clutch fork needs to be removed. The book gives it | |
| like this | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130031.jpg.html][IMG]http://… | |
| The bearing was not present on mine and the fork simply popped | |
| off the ball joint (I think the clip is worn) | |
| The ball joint | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130032.jpg.html][IMG]http://… | |
| The fork | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130033.jpg.html][IMG]http://… | |
| Next up is removal of the bell housing itself | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130030.jpg.html][IMG]http://… | |
| First is to remove the oil seal housing in the bell housing | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130034.jpg.html][IMG]http://… | |
| The 4 upper nuts where removed using a 1/4" Whitworth socket | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130035.jpg.html][IMG]http://… | |
| The 2 lower bolts and 1 nut were removed using a 7/16" socket | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130037.jpg.html][IMG]http://… | |
| I had to knock the assembly with a mallet to get it free enough | |
| to pull off | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130039.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130040.jpg.html][IMG]http://… | |
| There is some play in the upper bearing so that will be replaced | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130041.jpg.html][IMG]http://… | |
| The layshaft retaining bolt is next to be removed | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130042.jpg.html][IMG]http://… | |
| I used a socket on this and by holding the mainshaft by hand I | |
| was able to undo the bolt (it wasn't particularly tight) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130045.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130046.jpg.html][IMG]http://… | |
| The 4 fixings which connect the bell housing to the main gearbox | |
| casing are next to be removed. I used a 7/8" spanner and socket | |
| on a breaker bar to get these out. (as you can see the earlier | |
| oil seal housing bolts have been put back in place so I don't | |
| lose them) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130047.jpg.html][IMG]http://… | |
| The bellhousing was then tapped with a mallet and it started | |
| coming apart | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130048.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130049.jpg.html][IMG]http://… | |
| When the bellhousing comes off it brings the layshaft constant | |
| gear and conical distance piece with it | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130050.jpg.html][IMG]http://… | |
| This is how they should look on the layshaft | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130051.jpg.html][IMG]http://… | |
| Bellhousing | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130052.jpg.html][IMG]http://… | |
| The layshaft was then pulled out | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130053.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130054.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130058.jpg.html][IMG]http://… | |
| A view inside the main casing | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130056.jpg.html][IMG]http://… | |
| Reverse gear | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6130057.jpg.html][IMG]http://… | |
| Tomorrows job is to look at the selectors and fetch the | |
| mainshaft out to have a look at it | |
| #Post#: 89451-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: Arjan Date: June 14, 2014, 2:57 am | |
| --------------------------------------------------------- | |
| :thumbs: :thumbs: :thumbs: | |
| Keep it coming - very informative | |
| #Post#: 89483-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: samc88 Date: June 14, 2014, 6:03 pm | |
| --------------------------------------------------------- | |
| Right then, onto the selectors. | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140063.jpg.html][IMG]http://… | |
| First I removed the reverse and 1st gear detent springs using | |
| an 11mm spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140002.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140003.jpg.html][IMG]http://… | |
| There is a seal between the spring and the bracket | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140004.jpg.html][IMG]http://… | |
| Next was the top detent spring for 3rd gear, which cmae off | |
| using a 5/16" Whitworth spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140009.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140010.jpg.html][IMG]http://… | |
| Before removing the top cover, I had to remove the overdrive | |
| bracket which had been fitted to this gearbox. The nuts and | |
| bolts came off with a 1/4" whitworth spanner and socket | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140006.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140006.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140008.jpg.html][IMG]http://… | |
| The 2 nuts also need to come off using a 5/16" whitworth socket/ | |
| spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140012.jpg.html][IMG]http://… | |
| The stud came with the nut | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140013.jpg.html][IMG]http://… | |
| The cover can then be lifted off revealing the selector shafts. | |
| Be careful not to lose the 3 ball bearings that were under the | |
| detent springs | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140014.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140015.jpg.html][IMG]http://… | |
| The detent spring assembly | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140016.jpg.html][IMG]http://… | |
| There are 2 small rollers on top of the main casing, be careful | |
| not to lose these | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140018.jpg.html][IMG]http://… | |
| Select third gear and the selector shafts can then be lifted | |
| out. Its a bit fiddly to do this with the shafts in place but | |
| they do come out. First out is the reverse shaft | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140019.jpg.html][IMG]http://… | |
| Then the 3rd/4th shaft | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140020.jpg.html][IMG]http://… | |
| This has a small pin along the shaft, be careful it doesnt drop | |
| out or you'll never find it again | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140021.jpg.html][IMG]http://… | |
| First selector | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140022.jpg.html][IMG]http://… | |
| Revealing the mainshaft | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140023.jpg.html][IMG]http://… | |
| The bearing slides off the mainshaft | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140025.jpg.html][IMG]http://… | |
| As does the 3rd/ 4th synchro hub | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140026.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140027.jpg.html][IMG]http://… | |
| Mine doesnt look bad at all aoart from its missing a leaf spring | |
| (which I found in the bottom of the box) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140027.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140028.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140030.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140032.jpg.html][IMG]http://… | |
| Before drifting the mainshaft out, I decided to take the | |
| transfer box out to make everything a more manageable size | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140065.jpg.html][IMG]http://… | |
| Before starting this the brake back plate needs removing. Take | |
| out the split pin in the castle nut and undo the nut (I had to | |
| use an impact gun on this as it was tight and due to lack of | |
| rear mainshaft gear I cant put in gear) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140033.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140034.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140035.jpg.html][IMG]http://… | |
| The rear output flange then just slides off | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140036.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140037.jpg.html][IMG]http://… | |
| These 4 nuts holding the back plate to the speedo housing are | |
| next to be removed, again with a 5/16" whitworth spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140038.jpg.html][IMG]http://… | |
| Once thats off, take off the retaining nut and bracket for the | |
| intermediate shaft, again 5/16" whitworth | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140040.jpg.html][IMG]http://… | |
| Using a pry bar, you can withdraw the shaft | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140041.jpg.html][IMG]http://… | |
| Before taking it out fully, take off the bottom plate (check | |
| theres no oil in it first though, I forgot so ended up with a | |
| workbench covered in old EP90 :o ) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140042.jpg.html][IMG]http://… | |
| The shaft can now be withdrawn whilst you support the | |
| intermediate gear cluster | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140043.jpg.html][IMG]http://… | |
| The cluster can now be rolled out the box | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140044.jpg.html][IMG]http://… | |
| Revealing the thrust washers either side | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140045.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140047.jpg.html][IMG]http://… | |
| They're a bit worn so will get new ones | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140048.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140049.jpg.html][IMG]http://… | |
| Gears look good | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140050.jpg.html][IMG]http://… | |
| With that out of the way, the fastenings holding the gearbox to | |
| the transfer box can be removed (using you guessed it, a 5/16" | |
| whitworth socket) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140052.jpg.html][IMG]http://… | |
| Next the external fastenings were removed | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140053.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140054.jpg.html][IMG]http://… | |
| Allowing the boxes to be split | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140055.jpg.html][IMG]http://… | |
| With the transfer box out of the way, it was now time to remove | |
| the mainshaft. | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140065.jpg.html][IMG]http://… | |
| First task is to remove the mahoosive circlip holding the | |
| housing in place | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140056.jpg.html][IMG]http://… | |
| Then the mainshaft can be drifted downwards and out of the box | |
| (support the casing on bits of wood to give the shaft more room | |
| to come out the box) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140057.jpg.html][IMG]http://… | |
| Little bit of surface rust on one or 2 components but not bad | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140058.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140059.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140060.jpg.html][IMG]http://… | |
| No chips on the teeth at all which is something | |
| Next up is splitting the transfer box and front output shaft | |
| housing | |
| First remove the cover plate using a 1/2" spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140066.jpg.html][IMG]http://… | |
| Then remove the Detent spring using a 5/16" whitworth | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140068.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140071.jpg.html][IMG]http://… | |
| Remove the transfer selector fork pinch bolt using a 1/4" | |
| whitworth spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140073.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140074.jpg.html][IMG]http://… | |
| Next remove the fixings holding the housing to the transfer main | |
| case | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140075.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140076.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140077.jpg.html][IMG]http://… | |
| Once the output housing is free, remove the 4 wheel drive | |
| selector | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140078.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140079.jpg.html][IMG]http://… | |
| The dust cover can now be removed using a 3/16" whitworth | |
| spanner | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140080.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140081.jpg.html][IMG]http://… | |
| The shafts can then be drifted out gently | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140082.jpg.html][IMG]http://… | |
| Next remove the front output flange, which is exactly the same | |
| process as the rear one | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140083.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140084.jpg.html][IMG]http://… | |
| Revealing the oil seal housing | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140085.jpg.html][IMG]http://… | |
| Which can be pulled off once the nuts are removed | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140087.jpg.html][IMG]http://… | |
| The output shaft can now be withdrawn | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140088.jpg.html][IMG]http://… | |
| The bearing can now be drifted out. I used a 32mm socket on the | |
| end of a long extension bar as a drift for getting it out | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140091.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140092.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140093.jpg.html][IMG]http://… | |
| Now, as I have another spare output housing which was clean I | |
| decided to use that one | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140094.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140095.jpg.html][IMG]http://… | |
| I decided to rebuild the output housing as I have all the bits | |
| required to do it | |
| The bearing was greased and pressed in the housing using the | |
| trusty old fly press | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140097.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140098.jpg.html][IMG]http://… | |
| A gasket was then made for the oil seal housing (using the old | |
| one as a pattern) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140103.jpg.html][IMG]http://… | |
| The old oil seal was then prised out (put the housing pointing | |
| down in the vice, flanges resting on the jaws and punched the | |
| seal out) | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140104.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140105.jpg.html][IMG]http://… | |
| The new seal | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140106.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140108.jpg.html][IMG]http://… | |
| Smear the outside of the seal with hylomar blue | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140107.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140109.jpg.html][IMG]http://… | |
| Press the seal in place, I like to put a smear of grease on the | |
| lip to lubricate whatever gets pushed through it. | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140110.jpg.html][IMG]http://… | |
| The housing can then be bolted back on with the gasket and a | |
| smear of hylomar either side | |
| The front output shaft can be then put in place again. The | |
| flange can then be slid on, this is a spare one I have, the mud | |
| shield on the other one was a bit mis-shapen | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140111.jpg.html][IMG]http://… | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140112.jpg.html][IMG]http://… | |
| Washer in place | |
| [URL= | |
| http://s1126.photobucket.com/user/110samec/media/P6140113.jpg.html][IMG]http://… | |
| The nut is then put in place and torqued up to 85 lb/ ft | |
| Tomorrows job is selector shafts and strip down the transfer box | |
| I think | |
| #Post#: 89484-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: mandylandy Date: June 15, 2014, 1:55 am | |
| --------------------------------------------------------- | |
| Nothing short of BRILLIANT. | |
| I have a spare box that I dare not touch,maybe I will find the | |
| balls one day! | |
| Thanks x. :lightblb: :smilewide: | |
| #Post#: 89497-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: puddlejumper Date: June 15, 2014, 4:38 am | |
| --------------------------------------------------------- | |
| :thumbs: :thumbs: :thumbs: | |
| Fantastic thread, very useful.......well done | |
| #Post#: 89502-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: Serious Series Date: June 15, 2014, 9:42 am | |
| --------------------------------------------------------- | |
| When replacing transfer case intermediate gear as well as | |
| replacing brass faced washers worth getting some of part No | |
| 561197 which are a packing shim so that you can get the correct | |
| end float on the shaft they are rarely fitted but if two much | |
| end float then going on and off load gear train moves on shaft | |
| and is cause of some of the gearing noise. | |
| Where the gear teeth are rusted the gear will have lost its | |
| hardened surface so life of gear will be shortened . | |
| You can soak them in vinegar to remove full depth of rust to see | |
| how bad they are. | |
| Looks like a suffix A box as stated earlier. | |
| #Post#: 89505-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: Albert Ross Date: June 15, 2014, 10:39 am | |
| --------------------------------------------------------- | |
| Look closely at the pictures of the 3/4 synchro hub. There is a | |
| milling on the inner sleeve, and this faces the rear, as it fits | |
| over the retainer for the mainshaft cluster. Get it wrong, and | |
| you'll never stay in 3rd.... | |
| #Post#: 89507-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: samc88 Date: June 15, 2014, 11:12 am | |
| --------------------------------------------------------- | |
| Thanks for the advice guys! Albert Ross, thanks for that, I | |
| never noticed the difference between the ends, have marked it | |
| though. | |
| It is a suffix A, the reverse gear is on a bush which has a | |
| little bit of wear in it so I will replace it whilst Im at this | |
| stage. Looking at the gears and after some advice recieved | |
| elsewhere, 1st, 2nd, 3rd and the layshaft will be replaced. the | |
| dog teeth on the 1st and 2nd gear are chipped and 3rd is rusty | |
| #Post#: 89508-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: harryhedgehog Date: June 15, 2014, 11:23 am | |
| --------------------------------------------------------- | |
| Liking this, keep up the good work :thumbs: | |
| HHH | |
| #Post#: 89526-------------------------------------------------- | |
| Re: Sam's Gearbox Overhaul | |
| By: StuartN Date: June 16, 2014, 2:25 am | |
| --------------------------------------------------------- | |
| Very comprehensive, thank you. | |
| Sticky?? | |
| S | |
| ***************************************************** | |
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