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#Post#: 89542--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: clemo902 Date: June 16, 2014, 2:59 pm
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Good thread.
Quick question if I may?
I am currently re-building a suffix A main box (which also has a
factory re-build plate on the bellhousing, and has been coupled
to a transfer box with a B suffix at some point).
I have not yet taken apart the transfer box and front output
housing but will probably do so even though it worked fine, but
the question is whether it is normal to have a bit of rotational
play in the front output flange before the gears in the transfer
box and rear output shaft move?
I reckon the outside edge of the output flange rotates about
10mm (about 15 degrees angular movement according to my
daughters protractor) before the other gears in the transfer box
and the rear shaft move.
Thanks & sorry for the hijack !
#Post#: 89548--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 16, 2014, 4:12 pm
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Yes mine was like that. Its normal according to my granddad (as
long as its not a huge amount, like more than quarter of a
turn). I'll have a look in the book next time in the shed though
for the actual figure of whats acceptable or not
#Post#: 89592--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Serious Series Date: June 17, 2014, 11:35 am
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If you can post a pic of rear of front output shaft and the dog
gear it couples into you will understand why there is so much
play at front output shaft.
Have not got a photo handy.
#Post#: 89593--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Wooden Date: June 17, 2014, 12:17 pm
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First-class thread! Thanks for taking the time to take and share
so many pics, as well as your detailed step-by-step commentary.
When you're finished, this thread goes straight to the Tech
Archive where it will rightly belong.
:thumbs:
#Post#: 89741--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 21, 2014, 4:30 pm
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Right then, disassembling the mainshaft
I strted at the front end and worked back, starting with third
gear. The first job to do is to remove the snap ring (basically
a circlip but without the helpful little holes to get a pair of
pliers in). With help from my Dad I removed the clip with 3 thin
screwdrivers, its a bit awkward but doable
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150115.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150115.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150116.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150116.jpg[/img][/URL]
You can then withdraw the thrust washer and the third gear
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150117.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150117.jpg[/img][/URL]
Then withdraw the distance sleeve and bush
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150118.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150118.jpg[/img][/URL]
Then you can withdraw second gear and the thrust washer as well
as the front synchro cone
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150119.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150119.jpg[/img][/URL]
Next I removed the rear mainshaft bearing/ oil seal housing. I
had to use a set of pullers for this as I didnt want to damage
anything.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150120.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150120.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150121.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150121.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150122.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150122.jpg[/img][/URL]
To dismantle the rear part of the mainshaft remove the thrust
washer
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150123.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150123.jpg[/img][/URL]
It has 2 grooves on the forward face (facing the front of the
gearbox)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150124.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150124.jpg[/img][/URL]
First gear can now be removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150125.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150125.jpg[/img][/URL]
As can the first gear bush
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150126.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150126.jpg[/img][/URL]
The rear synchro cone is removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150127.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150127.jpg[/img][/URL]
As is the first-second synchro hub which looks decent according
to my granddad (hes done quite a few of these in the past), it
certainly operates freely enough but I think I'll swap the
detent springs and things whilst I'm at it and give a good dose
of looking at
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150128.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150128.jpg[/img][/URL]
The components split into front of mainshaft and rear, all cable
tied together to keep them in order
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150129.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150129.jpg[/img][/URL]
Next attention turned to the bellhousing again. I slackened off
the nuts for the bearing carriers at the back of the bellhousing
before knocking the bearing through, again using a suitable
socket as a drift
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150132.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150132.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150130.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150130.jpg[/img][/URL]
For the layshaft bearing carrier, the tab washer first needs the
tabs knocking flat
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150133.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150133.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150134.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150134.jpg[/img][/URL]
The nuts can then be undone using a 1/2" socket
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150135.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150135.jpg[/img][/URL]
The lifted off lock washer
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150138.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150138.jpg[/img][/URL]
The rear washer holding the studs can also be removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150139.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150139.jpg[/img][/URL]
and the bearing knocked out
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150140.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150140.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6150141.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6150141.jpg[/img][/URL]
Thats it for the mainshaft, attention then turned towards
stripping the transfer box
First task with this is to remove the speedo housing by removing
the 6 nuts and spring washers using a 5/16" whitworth spanner
again
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6210142.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6210142.jpg[/img][/URL]
Some of the studs came out with the nuts, as you can see one is
longer than the rest to go through the thickest part of the
housing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6210143.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6210143.jpg[/img][/URL]
The housing can now be pulled off
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6210146.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6210146.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6210147.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6210147.jpg[/img][/URL]
Between the housing and the transfer case are some shims. On my
spare transfer box, there were 3 but on this one there are 4
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6210149.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6210149.jpg[/img][/URL]
The worm gear. This isnt fixed to the shaft but interestingly it
runs off friction
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6210150.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6210150.jpg[/img][/URL]
Shall carry on with stripping it down tomorrow :)
So far the list of bits to change are:
Gaskets,
Seals,
Bearings,
Detent springs and balls,
Thrust washers,
1st gear,
2nd gear,
3rd gear,
Layshaft,
Bushes,
3rd/4th synchro hub (on closer inspection the teeth were worn)
Gear lever will get swapped off my old box as will the handbrake
back plate and drum
Cost for allthe bits will come to about £290 (no shitpart stuff,
pretty much all OEM). Not exactly cheap but saves me money
getting a recon box and its interesting seeing how it all goes
together, plus I like doing this sort of thing anyway (if I
didnt I wouldnt have got a series land rover I guess :D )
#Post#: 89752--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Albert Ross Date: June 22, 2014, 2:00 am
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Also, it will be more reliable than a used or "recon" item (they
cost more than this and don't get this kind of attention)
#Post#: 89754--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 22, 2014, 2:25 am
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Thats good to know :) How much of an overhaul to recon boxes
usually get then?
#Post#: 89756--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Albert Ross Date: June 22, 2014, 3:25 am
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Some bearings, some gears, all seals and gaskets... Normally the
ones with broken shafts etc get used as donors for gear
sets.... (If 2a) but it's not unheard of for three boxes or more
to be made into one.
#Post#: 90036--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Lucy Date: June 29, 2014, 4:16 am
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Couple of tips...
When you're removing the selectors, put it in 3rd gear before
you start, makes thinks much easier. I also strip these out
before removing the bell housing, gets everything clear so you
can get straight into pulling the lay and main shafts.
The big circlip in the transfer box just retains the rear
mainshaft bearing carrier, this can remain in place and the
mainshaft drifted out independently.
Also search the tech archive for "a bit about gearboxes" there's
a couple of threads with loads of photos on the workings of the
series box.
#Post#: 90038--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: June 29, 2014, 5:07 am
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I couldnt drift out the mainshaft from the bearing housing, it
just wouldnt budge even with a block of wood (to protect the
end) and a lump hammer
Yes putting it into third does make it much easier, the selctors
just lifted straight out I didnt even have to take them off the
shaft :)
i shall go and have a look at the thread now!
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