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#Post#: 65645--------------------------------------------------
OH nuts! Or one nut in the gearbox in particular
DIR By: tobyd
Date: June 24, 2013, 1:00 pm
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Hello,
I am in the middle of swapping the bellhousings on a S2a and S3
gearbox to gain a mechanical clutch on the S3.
I have removed the S2a bellhousing but the nut that holds the
lower shaft in place won't budge meaning the bellhousing will
only move about an inch.
I Can't seem to lock the gears to let me apply any force to the
nut. Any ideas how I can remove this?
Cheers
#Post#: 65646--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: RMS
Date: June 24, 2013, 1:03 pm
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I thought that with the gear lever removed, you could select two
gears (can't remember which) to lock it up :-?
#Post#: 65667--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: Albert Ross
Date: June 24, 2013, 2:20 pm
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Use an airgun....
#Post#: 65686--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: tobyd
Date: June 24, 2013, 3:15 pm
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I have an electric impact wrench. Even with the gears not locked
will that work? I wouldn't be in danger of damaging the gearbox?
#Post#: 65690--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: Albert Ross
Date: June 24, 2013, 3:29 pm
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Give it a go..... you might be surprised.
#Post#: 65702--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: Calum
Date: June 24, 2013, 4:01 pm
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You can select two gears at once, but you must remove the little
'bullets' inbetween the selector forks. If the forks etc are all
removed, then you should be free to flick the selector rings
inside the box and select two gears together. A good fitting
spanner and a crack with the copper mallet will probably see it
free. I think they are specced to be torqued up with a drop of
loctite on them?
#Post#: 65777--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: tobyd
Date: June 25, 2013, 6:59 am
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Well the nuts off and eventually wrestled the bellhousing off as
the layshaft was a tight fit.
Now putting it back together I can't get the last 1/2 to 1/4
inch tightened up. I feel sure I have the layshaft located i the
rear bearing but its just not doing. Can't decide if its just
the reverse of the tight fit, an incompatibility I don't know
about or something else - ideas welcome.
Toby
#Post#: 65779--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: Goose
Date: June 25, 2013, 7:42 am
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Don't force the rear bearing, they're woefully fragile and crap
at the best of times, If it's an unknown age, I'd recommend
replacing the rear bearing as a matter of course, as it's often
the first to fail - and ragging gearboxes in and out gets very
boring very quickly.
#Post#: 65828--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: tobyd
Date: June 25, 2013, 12:42 pm
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Thanks for the advice Goose but read it too late - damaged the
rear bearing so will have to order another - just as I'd worked
out a great method for getting the whole thing together.
Best get a part on order. The outer casing of the bearing is
still in the gearbox - can this be reused as getting it out
would be a nightmare?
Also swapped the front layshaft bearing from the S3 to the S2 as
the latter was a bit smaller. All that time spent and its still
in bits on the bench - ggggrrrrr.
Toby
#Post#: 65872--------------------------------------------------
Re: OH nuts! Or one nut in the gearbox in particular
DIR By: estwdjhn
Date: June 25, 2013, 3:49 pm
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--- Quote ---
> The outer casing of the bearing is still in the gearbox - can
this be reused as getting it out would be a nightmare?
--- End Quote ---
I'm afraid not - it's matched to the inner bearing. If it's the
original it's also probably worn into ridges - that's where most
of the bearing whine on a tired series box comes from.
Is this a Series 2 or Series 3 main gearbox casing? If it's a
series 3, split the transfer box and there will (almost
certainly - every series 3 box I've ever had has them) be
revealed two small holes at the back of the main box casing
which allow you to drift out the offending bearing from behind.
Failing this, your options are:
1: Drill two suitable holes yourself (Series 2 and 2a boxes
generally don't have the holes drilled) - if you get stuck, I've
a gearbox in the garden with said hole in it I could photo so
you know where to drill.
2: Make up a really good fitting wooden dowel that just goes
inside the bearing race. Pack the inside of said bearing race
with grease, insert dowel, wallop with a hammer, and if it's
your super lucky day the bearing race may hydraulic out. In my
experience, usually it doesn't.
3: Split the Xfer box off and stand the main casing on end, nose
downwards. Heat the outside of the main box rapidly round the
bearing housing, then hit said housing sharply with a hammer,
and the bearing may fall out. In my experience, it never does,
however I did discover it's very easy to get the main gearbox
case to start to melt.
Methods 2 and 3 both feature in the workshop manual - I think
method 1 may also feature in later additions. I personally would
only ever attempt method 1 (as I've never had the others work,
but I though it's only fair to include them for the sake of
completeness.
One other option that might will work is a suitably assembled
slide hammer hooked into the bearing, but I've never had one
available to try.
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