20 replies to this topic

[johnnyblaze]

am building the gearbox for my race mini, its all striped apart, except............... i cant get the 2nd gear thrust washer to come off i pushed and prodded at the detent pegs and twisted the washer full 360' trying at every interval, would not come off.

is there some special way to remove this ?

all the vids i can find including guessworks vid all show re-asslembly of the shaft, i would think its the opposite if installing , looks like the intervals dont line up with the splines on the mainshaft, or am i dreaming?

also im washing all parts of the box and gears etc, should i be pulling the synchro hubs apart as well to clean them?

cheers
kerrin

[Guess-Works.com]

Removing the 2nd gear thrust is a bit of a skill, nack, luck if you wish....

First of all don't take the 3rd gear off until the 2nd gear is off, if you've already done that, then put it back on, it makes life easier...

Put the shaft in a vice, 2nd gear upward.

Do what you've probably already been doing which is push in one plunger, rotate the ring as far as you can, and then push in the second ( this is more difficult ) and rotate the ring so it lines up with the splines. Next comes the nack, place a large flat screwdriver or wedge between 2nd and 3rd gears gently applying pressure to the 2nd gear, slowly turn the 2nd gear, whilst using a small ( jewellers ) screwdriver between the ring and the gear to cajole it into position, and with the upward pressure will ping when its in the right place...

Pull the synchro's apart if you want to, some times balls can stick in, but be aware you need to put them back together...

http://www.guess-wor...play.htm?id=279

http://www.guess-wor...play.htm?id=236

[johnnyblaze]

ahhhhhh thanks yes i was doing it with 3rd gear removed , will try it the way you have said when i get home from work tonight, see how much more blood i can loose

will give an update tonight

cheers
kerrin

[johnnyblaze]

awesome , did as you said guessworks and bingo popped right off thanks for that.

gearbox is now fully stripped and everything is cleaned up apart from the main case that wont take long.

1 thing are all 4 bulkrings the same , as in they can be put on any part they arnt spot specific?

kerrin

[johnnyblaze]

having a bit of trouble with the gearbox, fitted all the new parts checked out the operation of the selectors when installed , work how they should pop the main shaft in and reverse, selects reverse , will operate the syncro hub as per normal the 1 closest to the centre of the box but the syncro hub thats operated by the selecter with the roll pin in it doesnt seem to move much , im just wandering if i put 1 syncro hub together the wrong way, does anyone have a detaild drawing of how they should fit, together? getting a bit pissed off ive had it apart 3 times now

[Guess-Works.com]

She-zam ! ( like a genie )

Take a pic of what it looks like, this will first check you have the synchro's in the right way round...

Is that's ok, I'm assuming you took the synchro hubs apart, in which case you may have put the back together wrong, but that's best explained after seeing the picture of the box.

[johnnyblaze]

this moves all the way left towads box case end but only as far as shown to the right , looking at piks

[johnnyblaze]

just wandering if i have the centre of the hub backwards as theres a 1mm step lip on on side and about a .4mm lip on the other , on the parts where the shaft passes through

[Guess-Works.com]

You have got the springs and balls in the synchro hub haven't you ?

[johnnyblaze]

yeh they were in there i moved it by hand in my anger and they came out so i have to pull it apart again and put them back in

[Guess-Works.com]

there seems to be no obvious displacement of the 3rd motion shaft, so I suspect that there's something wrong with the synchro hubs, or the selector forks having restricted movement, either way, it's all coming out again.

[johnnyblaze]

so thought id better ask a person who knows since this will be the 4th time apart , just to put the springs and balls back in the hub
im getting fast at assembly of the hubs.

[Guess-Works.com]

while it's out, carefully check the operation of everything before re-assembling, ie forks, synchro hubs both on and off of the main shaft, and also check the alignment of the splines within the hubs.

[johnnyblaze]

yes it is, with out the shaft in the selecter forks all move freely in accordance to your video, so thats why im wandering if i have that hub backwards, would that .5mm of step be enough to screw it up

the other hub has the pronunced snout on it so i can tell thats orintated correctly be looking at your video

[johnnyblaze]

alignments of the shafts? i have them so that the outer halfs openings line up with the first set of splines on the inner ie all 3 openings look the same no unequal splines on one opening, the new bulkrings have any thing to do with it?