Transaxale tools and rebuild

[Gary Whitaker]

Next the 4th gear bush

[Gary Whitaker]

4th gear and a little oil

[John A. Ross]

Almost tempted to split that early box myself now.

Its great your adding all the liottle easy to do slips ups Gary,

John

[PMCG]

Great stuff here.

[Gary Whitaker]

From the last pic above you can see the bush protruding above 4th gear this has to be crushed by the 4th selective washer to clamp the bushes as they are fixed .
so we have to work out the crush amount plus the gear END FLOAT and this it doesn't mention anywhere in the manual so if all the bush heights aren't correct you could lock the box up.
I'll explain below how this can happen and how important it is to have the pinion head tool RG 365

[Gary Whitaker]

You now fit the .200" washer that came with the pinion head tool.it doesn't matter if it's not .200" as long as it can spin when you push the preload washer down on top

[Gary Whitaker]

Now put the preload washer that you selected earlier and push down check the gap with a feeler gauge note the reading

[Gary Whitaker]

Now fit another washer thicker than the test washer plus the feeler gauge doesn't matter how much thicker at this time just plus the reading so when you push down the preload washer now clamps the 4th selective washer and it can't spin you can put more pressure on if you put the bearing on top.
make sure you measure only the endfloat as the feeler gauge only has a small lip to go under
This is your endfloat before crush

[Gary Whitaker]

Now this is where it didn't go right when I measured the endfloat I only had .007".
But I had new bushes so had to crush them between .006 and .012".
If I had just gone by the book and decided to crush by .008" it would have locked the box
I found the problem was 4gear bush was undersize on the length so I made a new one to top limit .
It doesn't tell you in the manual what the endfloat should be but many other gearboxes seem to run at .002" to .006" so bear in mind to check this and take it into consideration then selecting the crush amount

[Gary Whitaker]

Now the maths, it's gives it all in the manual .
test washer.200"
Plus feeler .012"
Crush. .010"
Washer req .220"
endfloat before crush .014"
Gearbox endfloat .004"

[Gary Whitaker]

Now fit the .220" washer and the preload washer.
fit a new tolerance washer if you have one and fit the input shaft

[Gary Whitaker]

The reason for the accuracy of the bushes and selective washer is to put the bulk rings and selector forks in the correct place and as can be seen in the pic that the selector shaft can smoothly slide across the 2 selector forks and that the selector forks run in the centre of the bulk rings so they don't wear

[Gary Whitaker]

You can now put the next casting on ,make sure it's spotlessly clean and put a good quality sealant.
put the sealant completely round all the holes so you don't get a leak from the studs

[Dave Lane]

Fsinating stuff and way past my skill set , rather than try and get it working again I made a lamp out of it - seemed easier for me ( PS the gears out of order is deliberate )

[Gary Whitaker]

Put the flat washers and nuts on and tighten in stages as per manual, fit the reverse gears and tighten the nuts hand tight only