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#Post#: 89445--------------------------------------------------
Sam's Gearbox Overhaul
By: samc88 Date: June 13, 2014, 4:31 pm
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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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130013.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130013.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130014.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130014.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130015.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130015.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130016.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130016.jpg[/img][/URL]
First task is to remove the gearlever.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130018.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130018.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130017.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130017.jpg[/img][/URL]
I then removed the shorter bolt at the front using an 11mm
spanner. (there should be 2 bolts but only one was present)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130021.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130021.jpg[/img][/URL]
The bolts holding the main gear lever in place
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130022.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130022.jpg[/img][/URL]
The 2 smaller bolts also hold down this plate in the bellhousing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130023.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130023.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130024.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130024.jpg[/img][/URL]
The whole gear lever assembly can be pulled off
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130026.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130026.jpg[/img][/URL]
The selectors
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130028.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130028.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130029.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130029.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130031.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130031.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130032.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130032.jpg[/img][/URL]
The fork
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130033.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130033.jpg[/img][/URL]
Next up is removal of the bell housing itself
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130030.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130030.jpg[/img][/URL]
First is to remove the oil seal housing in the bell housing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130034.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130034.jpg[/img][/URL]
The 4 upper nuts where removed using a 1/4" Whitworth socket
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130035.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130035.jpg[/img][/URL]
The 2 lower bolts and 1 nut were removed using a 7/16" socket
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130037.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130037.jpg[/img][/URL]
I had to knock the assembly with a mallet to get it free enough
to pull off
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130039.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130039.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130040.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130040.jpg[/img][/URL]
There is some play in the upper bearing so that will be replaced
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130041.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130041.jpg[/img][/URL]
The layshaft retaining bolt is next to be removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130042.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130042.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130045.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130045.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130046.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130046.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6130047.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130047.jpg[/img][/URL]
The bellhousing was then tapped with a mallet and it started
coming apart
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130048.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130048.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130049.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130049.jpg[/img][/URL]
When the bellhousing comes off it brings the layshaft constant
gear and conical distance piece with it
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130050.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130050.jpg[/img][/URL]
This is how they should look on the layshaft
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130051.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130051.jpg[/img][/URL]
Bellhousing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130052.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130052.jpg[/img][/URL]
The layshaft was then pulled out
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130053.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130053.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130054.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130054.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130058.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130058.jpg[/img][/URL]
A view inside the main casing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130056.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130056.jpg[/img][/URL]
Reverse gear
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6130057.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6130057.jpg[/img][/URL]
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
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:thumbs: :thumbs: :thumbs:
Keep it coming - very informative
#Post#: 89483--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 14, 2014, 6:03 pm
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Right then, onto the selectors.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140063.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140063.jpg[/img][/URL]
First I removed the reverse and 1st gear detent springs using
an 11mm spanner
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140002.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140002.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140003.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140003.jpg[/img][/URL]
There is a seal between the spring and the bracket
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140004.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140004.jpg[/img][/URL]
Next was the top detent spring for 3rd gear, which cmae off
using a 5/16" Whitworth spanner
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140009.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140009.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140010.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140010.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140006.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140006.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140006.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140006.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140008.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140008.jpg[/img][/URL]
The 2 nuts also need to come off using a 5/16" whitworth socket/
spanner
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140012.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140012.jpg[/img][/URL]
The stud came with the nut
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140013.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140013.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140014.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140014.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140015.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140015.jpg[/img][/URL]
The detent spring assembly
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140016.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140016.jpg[/img][/URL]
There are 2 small rollers on top of the main casing, be careful
not to lose these
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140018.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140018.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140019.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140019.jpg[/img][/URL]
Then the 3rd/4th shaft
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140020.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140020.jpg[/img][/URL]
This has a small pin along the shaft, be careful it doesnt drop
out or you'll never find it again
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140021.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140021.jpg[/img][/URL]
First selector
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140022.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140022.jpg[/img][/URL]
Revealing the mainshaft
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140023.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140023.jpg[/img][/URL]
The bearing slides off the mainshaft
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140025.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140025.jpg[/img][/URL]
As does the 3rd/ 4th synchro hub
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140026.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140026.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140027.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140027.jpg[/img][/URL]
Mine doesnt look bad at all aoart from its missing a leaf spring
(which I found in the bottom of the box)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140027.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140027.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140028.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140028.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140030.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140030.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140032.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140032.jpg[/img][/URL]
Before drifting the mainshaft out, I decided to take the
transfer box out to make everything a more manageable size
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140065.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140065.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140033.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140033.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140034.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140034.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140035.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140035.jpg[/img][/URL]
The rear output flange then just slides off
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140036.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140036.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140037.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140037.jpg[/img][/URL]
These 4 nuts holding the back plate to the speedo housing are
next to be removed, again with a 5/16" whitworth spanner
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140038.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140038.jpg[/img][/URL]
Once thats off, take off the retaining nut and bracket for the
intermediate shaft, again 5/16" whitworth
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140040.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140040.jpg[/img][/URL]
Using a pry bar, you can withdraw the shaft
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140041.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140041.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140042.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140042.jpg[/img][/URL]
The shaft can now be withdrawn whilst you support the
intermediate gear cluster
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140043.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140043.jpg[/img][/URL]
The cluster can now be rolled out the box
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140044.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140044.jpg[/img][/URL]
Revealing the thrust washers either side
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140045.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140045.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140047.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140047.jpg[/img][/URL]
They're a bit worn so will get new ones
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140048.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140048.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140049.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140049.jpg[/img][/URL]
Gears look good
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140050.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140050.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140052.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140052.jpg[/img][/URL]
Next the external fastenings were removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140053.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140053.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140054.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140054.jpg[/img][/URL]
Allowing the boxes to be split
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140055.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140055.jpg[/img][/URL]
With the transfer box out of the way, it was now time to remove
the mainshaft.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140065.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140065.jpg[/img][/URL]
First task is to remove the mahoosive circlip holding the
housing in place
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140056.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140056.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140057.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140057.jpg[/img][/URL]
Little bit of surface rust on one or 2 components but not bad
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140058.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140058.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140059.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140059.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140060.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140060.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140066.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140066.jpg[/img][/URL]
Then remove the Detent spring using a 5/16" whitworth
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140068.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140068.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140071.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140071.jpg[/img][/URL]
Remove the transfer selector fork pinch bolt using a 1/4"
whitworth spanner
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140073.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140073.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140074.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140074.jpg[/img][/URL]
Next remove the fixings holding the housing to the transfer main
case
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140075.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140075.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140076.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140076.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140077.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140077.jpg[/img][/URL]
Once the output housing is free, remove the 4 wheel drive
selector
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140078.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140078.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140079.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140079.jpg[/img][/URL]
The dust cover can now be removed using a 3/16" whitworth
spanner
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140080.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140080.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140081.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140081.jpg[/img][/URL]
The shafts can then be drifted out gently
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140082.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140082.jpg[/img][/URL]
Next remove the front output flange, which is exactly the same
process as the rear one
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140083.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140083.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140084.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140084.jpg[/img][/URL]
Revealing the oil seal housing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140085.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140085.jpg[/img][/URL]
Which can be pulled off once the nuts are removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140087.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140087.jpg[/img][/URL]
The output shaft can now be withdrawn
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140088.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140088.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140091.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140091.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140092.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140092.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140093.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140093.jpg[/img][/URL]
Now, as I have another spare output housing which was clean I
decided to use that one
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140094.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140094.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140095.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140095.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140097.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140097.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140098.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140098.jpg[/img][/URL]
A gasket was then made for the oil seal housing (using the old
one as a pattern)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140103.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140103.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140104.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140104.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140105.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140105.jpg[/img][/URL]
The new seal
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140106.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140106.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140108.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140108.jpg[/img][/URL]
Smear the outside of the seal with hylomar blue
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140107.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140107.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140109.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140109.jpg[/img][/URL]
Press the seal in place, I like to put a smear of grease on the
lip to lubricate whatever gets pushed through it.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140110.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140110.jpg[/img][/URL]
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=
HTML http://s1126.photobucket.com/user/110samec/media/P6140111.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140111.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140112.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140112.jpg[/img][/URL]
Washer in place
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6140113.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6140113.jpg[/img][/URL]
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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