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#Post#: 90634--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: July 11, 2014, 5:10 pm
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Right update time, stripping the transfer box!
Before removing the shaft, I checked how far into the casing
the bearing sits (6mm) as a reference for when I refit the
bearing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6220154.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6220154.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6220151.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6220151.jpg[/img][/URL]
The shaft is first drifted rearwards with a mallet
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6220152.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6220152.jpg[/img][/URL]
The large circlip is then removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6220153.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6220153.jpg[/img][/URL]
Next I drifted the bearing inner race off the shaft (apologies
for the blurry action shot)
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172225_zps1413faae.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172225_zps1413faae.jpg[/img][/URL]
Then the circlip holding the thrust washer and the gears in
place was removed allowing the shaft to removed
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6220155.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6220155.jpg[/img][/URL]
The thrust washer
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P6220156.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P6220156.jpg[/img][/URL]
With the shaft out I could then drift out the other bearing race
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172229_zps00f39529.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172229_zps00f39529.jpg[/img][/URL]
(This next bit is from my other thread showing the various bits
of the shaft) as I forgot to take photos this time
"The order the bits are on the shaft
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172231_zps7f980d49.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172231_zps7f980d49.jpg[/img][/URL]
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172232_zpsf1208c03.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172232_zpsf1208c03.jpg[/img][/URL]
Bearing outer race, inner race, circlip holding gears on and
thrust washer
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172233_zps9a79addc.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172233_zps9a79addc.jpg[/img][/URL]
High gear
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172234_zpsfb32e634.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172234_zpsfb32e634.jpg[/img][/URL]
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172235_zps609a2e24.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172235_zps609a2e24.jpg[/img][/URL]
Low gear
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172236_zps96004224.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172236_zps96004224.jpg[/img][/URL]
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172237_zps66c976d3.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172237_zps66c976d3.jpg[/img][/URL]
Shaft with bearing
[URL=
HTML http://s1360.photobucket.com/user/samclarke95/media/P2172238_zpsf2761b23.jpg.html][IMG]http://i1360.photobucket.com/albums/r645/samclarke95/P2172238_zpsf2761b23.jpg[/img][/URL]
"
Today I sorted out the workshop to get ready for rebuild
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7110173.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7110173.jpg[/img][/URL]
and immediately set about making a mess sorting out the parts I
have :D
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7110174.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7110174.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7110175.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7110175.jpg[/img][/URL]
Rebuild starts tomorrow :)
#Post#: 93948--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: October 22, 2014, 3:20 pm
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Right been a while since last update. I have actually finished
the box and its running well now (thank God), I just havent had
the time to carry on with this thread.
Right back to business,
First thing I did was to overhaul the bellhousing.
The input shaft was drifted out of the bellhousing (backwards)
leaving this:
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7120194.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7120194.jpg[/img][/URL]
Using circlip pliers, the circlip was removed. This will be
replaced. Note: there is a thrust washer under the circlip
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7120195.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7120195.jpg[/img][/URL]
Holding the input shaft (gently) in the vice, the bearing could
be heated up with the blow torch until it fell down the shaft
after a slight tap with the mallet
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130196.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130196.jpg[/img][/URL]
The new bearing was heated up with a blow torch until it could
be dropped into place on the shaft and the thrust washer was
replaced
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130197.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130197.jpg[/img][/URL]
Circlip being fitted using circlip pliers
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130198.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130198.jpg[/img][/URL]
The assembled input shaft. The seal land looks good so no
worries there of any pitting ragging the new oil seal
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130199.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130199.jpg[/img][/URL]
The bellhousing casing was rested on top of the vice so there
was enough room underneath for the input shaft to drop down. The
casing was then heated up until the bearing could be dropped
into place
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130200.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130200.jpg[/img][/URL]
The layshaft bearing could then be dropped into place using the
same technique (heating the casing up) an the bearing carriers
can be put in place (The input shaft bearing carriers are
handed)
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130201.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130201.jpg[/img][/URL]
Layshaft bearing cover plate thing goes down with the lip going
against the bearing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130202.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130202.jpg[/img][/URL]
Nuts and lockwasher in place with the tabs being lifted up. You
might find putting a prybar through the clutch fork hole and
tapping that is easier for lifting the tabs
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130203.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130203.jpg[/img][/URL]
The bellhousing was then wrapped in rags to keep everything
clean and put aside till later
#Post#: 93949--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: October 22, 2014, 3:34 pm
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Now then, rear mainshaft bearing housing overhaul.
I started by removing the old oil seal, removing the large
circlip which retains the bearing and then drifting out the old
bearing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130205.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130205.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130206.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130206.jpg[/img][/URL]
The manual says to put loctite on the outer race before fitting
to hold into the housing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130207.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130207.jpg[/img][/URL]
New bearing being pressed into the housing
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7130208.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7130208.jpg[/img][/URL]
Once the bearing was pressed in and the circlip refitted, I
fitted the oil seal (a corteco one)
Here you can see the layshaft outer race in position (more on
this later), this was done at this point for convenience.
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200236.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200236.jpg[/img][/URL]
Again loctite was used but on the housing itself this time
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200237.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200237.jpg[/img][/URL]
Drifting the housing into place
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200240.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200240.jpg[/img][/URL]
The circlip which holds the housing in place can be refitted
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200241.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200241.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200242.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200242.jpg[/img][/URL]
#Post#: 93955--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Mendit Date: October 23, 2014, 1:15 am
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Got to say brilliant fab photos and has been said may give me
the confidence to dabble
Well done
#Post#: 96225--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: February 16, 2015, 3:31 pm
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Some more pics, will add text later
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200245.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200245.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200246.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200246.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200247.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200247.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200248.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200248.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200249.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200249.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7200250.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7200250.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7220251.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7220251.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7220252.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7220252.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7220253.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7220253.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260254.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260254.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260255.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260255.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260256.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260256.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260257-1.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260257-1.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260258.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260258.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260259.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260259.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260260.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260260.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260261.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260261.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260262.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260262.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7260263.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7260263.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7270264.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7270264.jpg[/img][/URL]
[URL=
HTML http://s1126.photobucket.com/user/110samec/media/P7270265.jpg.html][IMG]http://i1126.photobucket.com/albums/l606/110samec/P7270265.jpg[/img][/URL]
#Post#: 96837--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: AntC Date: March 30, 2015, 9:37 am
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This is so good! How did you get the layshaft rear bearing race
out of the gearbox casing?
#Post#: 96851--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: Arjan Date: March 31, 2015, 4:02 am
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:thumbs: :thumbs: :thumbs: :thumbs: :thumbs: :thumbs:
Awesome read !
Many thanks.
#Post#: 96859--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: nickjaxe Date: March 31, 2015, 3:36 pm
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Got my main box in bit on my bench at the moment....spending a
lot of time to get the end float correct on 2nd 3rd gear...think
I may need an over sized washer and a new brass sleeve.
Quite a fiddle of a job.
#Post#: 96861--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: samc88 Date: March 31, 2015, 4:16 pm
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AntC: The casting has two holes behind the outer race. I heated
up the casing around it first and then lightly tapped it and it
came out easily
#Post#: 96862--------------------------------------------------
Re: Sam's Gearbox Overhaul
By: harryhedgehog Date: March 31, 2015, 4:23 pm
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>Htlr<
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