37 replies to this topic

[Jupitus]

Blatant bumpage!! I have ordered a welder now

Oh... and 2 core rad arrived, ta JG.

[Bass Man]

P.S. I'm signing up on a welding night school course!!

I want to do that but I haven't found one at the level I want, ie I don't want qualifications.......

[Jupitus]

P.S. I'm signing up on a welding night school course!!

I want to do that but I haven't found one at the level I want, ie I don't want qualifications.......

Farnborough College of Tech - 6-8pm one night per week for 10 weeks, £230 FYI about 40 mins from Waterloo.

Edited by Jupitus, 04 July 2007 - 04:10 PM.

[miniboo]

not a bad price that.

but why not get some scrap metal and just have a go. there are online tips and tutorials you can use

[Jupitus]

not a bad price that.

but why not get some scrap metal and just have a go. there are online tips and tutorials you can use

Well I've ordered a welder and gas conversion kit and gas bottle from BOC so I will have a go ahead of the course... I did some gas welding when I was about 18 so I do know the basics... just a bit older and shakier these days

[Guess-Works.com]

I use to puch the single roller bearing out, which why I eventually said "sod that" and built the tool..

If you want one making I'll hapilly oblige, as I have a number of fubared diff cages around....

[Jupitus]

I use to puch the single roller bearing out, which why I eventually said "sod that" and built the tool..

If you want one making I'll hapilly oblige, as I have a number of fubared diff cages around....

Thanks JG - I'll have another crack at it this weekend first, perhaps having the weld redone on my improvised slide hammer and maybe with a punch... if I'm still stuck I may be onto you

[Jupitus]

Righty Ho - Got the nut re-welded securely on the tube... looking good I thought... hooked it all up on the bench with the long slide hanging down and a weight lifting weight on the t-bar at the end... held it all steady and got the Mrs to lift the weight then 1...2...3.... DROP!!!

The T-Bar weld broke

I had a good look around what was in the garage, and found that the bolt that fits the other end of the tube is the same size as the one on my puller!

Puller on bench with bolt through hole... offer up the 'box with the tube already on the shaft and get it threaded. The gearbox is now hanging off a bolt through my bench... whack a few times with mallet, lift and drop a few times... no luck...

Get trolley jack out, rest front on box and wind up the jack to push on bottom of bench... lever gently .... gently.... gently... enough tension there to hold the whole jack in situ.... and........

Stop! The bench is starting to give way!!

Dear oh dear oh me... I've left it hanging there for now while I ponder life in general

[Jupitus]

I use to puch the single roller bearing out, which why I eventually said "sod that" and built the tool..

If you want one making I'll hapilly oblige, as I have a number of fubared diff cages around....

Right! I give up!!! The bloody bolt inside the tube has now come loose, so out of the window goes my plan to get my trolley jack and break the whole lot to pieces!!!

JG - Please can you PM me a price? Many thanks!!!

[Guess-Works.com]

I'll get onto it, it's the cost of postage which may ramp it up a bit....

[Jupitus]

I'll get onto it, it's the cost of postage which may ramp it up a bit....

No worries JG, just want this sorted now

[Jupitus]

Sorry to be a PITA, JG, but I wondered if you came up with anything for me?

Ta muchly....

[Jupitus]

JG - I love you and I want to have your babies

That's the input shaft and bearing out now, so progress can resume!!

You star... many thanks indeed!!

[Jupitus]

Ok folks... I have managed to get the 'box dismantled now, thanks to Guessworks help very kindly providing me a suitable pulling tool (the double roller bearing came out a dream, by the way).

Now then... I have the mainshaft which still has (I think) gears 2 and 3 on it, and I have looked at JG's rebuild thread and I can see where you put 2 and 3 onto the shaft there are springs and the like to hold them in place... how do I remove 2nd and 3rd from the shaft though?

I also have the little springs and balls... do these just squash into place as I fit the syncros/gears together?

Ta

[Guess-Works.com]

You're now at the fiddly bit of gearboxes...

Protect the shaft with a little rag and place reasonbly firmly in a vice, pointing upwards ( I like to take 2nd off first as it's a little more fiddly than 3rd )

You'll see the two detents located in a twist lock, push one of them in using a very fine screwdriver ( these little cheapo silver screwdrivers are great for this ) and then using another turn the locking plate round to hold it in, you can then push the other detent in and do same...

At this point it's handy to get a LARGE screwdriver and place between the gears, gently using it as a lever to push the gear upwards, and then fiddling with the locking plate move that into position, when free the gear will pop off under the light pressure being applied on the big screwdriver. Withdraw gear, lokcing plate and then detents, spring and finally bearing race ( don't loose this

The 3rd speed is similar but only has one detent.

refitting is the reverse of the above

Synchros, it's a bit of a nack but is not difficult...

Place the outer ring on a nice flat surface, after placing the spings in the sychro hub, offer this up to the outer ring ( making sure you have them the right way round ) , and slide in half way so you can see the holes... Place all 3 balls in location and hold in with fingers... then using a suitable tool ( screwdriver ) press one of the ball in against the spring and then press down on the hub (stops the ball shooting back out)... while keeping downward pressure, turn the syncro round to the next ball, and do same again, downward pressure to be retained over both balls.... with the third when you press that in the synchro should snap together.

I've also heard stories of piston ring compressors being used, but the above does for me...