Not alot going on at the moment! I have had some issues with my other cars; Mini JCW has a knackered clutch, cracked windscreen and a noisy timing chain.....all cheap and easy to fix im sure! and the family BMW estate decided it wasnt going to start. Thankfully the BMW is back up and working (not really sure how or why) but I am putting it down to not using it and the cold weather. As a decent battery charge and the milder weather seemed to sort it out. The JCW has been taken off the road whilst I amass some funds to get it back to full health and Im not sure at the moment if im going to do the work myself or take it somewhere. Either way it wont be quick fix as I may do the turbo and some other general refresh stuff whilst its off the road especially as it will far easier with the engine out of the car to do the timing chain and clutch and as its a smidge off 90k miles it probably needs it.
In classic mini related news I have been working on the primary gear and idle gear and getting the box ready to fit:
First of all the gearbox mounting holes needed to be drilled out to 8.5mm to take the larger 5/16 bolts that come with the MED copper gasket Kit:
All done ready to go:
Next was to remove the old idler gear bearing from the transfer case:
I bought myself a cheap blind bearing puller kit off ebay and it did a pretty decent job:
Then this needed to be installed as I will be running a roller bearing idler:
And then pressed into position:
Next was the primary gear. thankfully I had amassed various parts over time (I also had bought a brand new washer C clip and bush so the old stuff was just in case) so I could pick and choose to get the correct clearence:
Everything went together fine initially and checked the clearence with the DTI and although in the upper reaches of the Haynes tolerance it was acceptable. This is where things started to get a little odd. Rotated the primary gear and thought I would check again just to be sure and I was now over tolerance. kept rotating and kept getting different figures. At first I thought my DTI was messing about or there was some slack in the magnetic base, but this checked fine. Then I thought it was the bush at the base of the primary gear but again this was checked and found to be completely flat. So then I thought it must be the C clip or washer......errr nope. it turns out its in the primary gear itself:
This vid shows the 0.04mm of runout on the top of the gear. Now obviously I didnt think this was correct (even though the runout is very small in real terms) and contacted Minispares (who supplied the gear). I was subsequently contacted by a very helpful chap who thought that it was likely to be from the play from the lower (internal to the primary gear) brass floating bush and nothing to be concerned about especially as the clearence issue came and went. He also suggested running at the top range of the Clearence value to ensure there was no issue.
So once again what should have been a simple job turned into something that took 5 times as long and lasted more than a week!! However box should hopefully be fitted to block this coming week and then covers and clutch etc can go on and it can be buttoned up and finished off. Just contemplating getting the engine dyno'ed so it can go into the car run in and set up.......
Edited by robj2502, 15 February 2019 - 09:39 AM.