so, having found out my gearbox is a hockley, and having it rejected by quaife, thought i'd just rebuild it myself!
not a big deal, except for fifth gear, which had somehow seized so hard onto the shaft, it took me all day to remove it yesterday!
you need to remove it first before the gears will come out of the sandwich plate.
the box arrived back minus its selector assembly, that was in a bag with it, so, having sworn and faffed alot with the fifth gear, here's what we started with today
as you can see, quite a few bits! the main reason for the rebuild was the missing synchro lug on second gear, i have a spare box at the garage with nearly new synchro hubs on it, so stripped that to bits to get the spares, the started to strip the main shaft on my SCCR and ,made the best box out of the two, thats why there's two fifth gear selectors in the above pic, the one in my spares box had snapped at some point and been welded up, didnt use that one obviously!
this is the offending fifth gear, is quite a tight fit!
the gear set out of the plate, is held in with tow circlips, one normal and one external tagged
so, in the vices soft jaws and away we go!
got the pu;ller out and removed first gear, having previosuly removed a circlip
this is the broken bit on the first/second synchro, note missing lug
so, bit of fiddling, and a new one is in
then refitted first, and the bearing retaining circlip, and the bearing it retains
then get the newly painted sandwich plate
hold the gears all meshed up, then refit into plate, retaining with a cirlip on each shaft
now time to refit fifth! is one million times easier when you can heat it in isolation from the shaft
on she goes, then fit a circlip, and fit two thrust washer halves to the other shaft, and a wrap around roller bearing
thrust washer comes in two bits so it can be fitted into the groove on the shaft
now fit reverse gear and its selector, then first/second gear selector
then fit thrid/fourth selctor,fifth gear selector, and then fifth gear itself and its synchro runner
this goes in here to act as a fifth gear detent
then the gear and runner go on
then fit the reverse detent, stops you getting reverse when you dont want it!
then fit the roll pinsin the selector rods, you can assemble these 180 degrees out, but you'll soon know, as the box will be stuck in one gear or another!
then finally time to fit the corss shaft and detents that hold the gears in once selected, the longer one goes in the thrid/forth gear shaft
refit end cover, then pop the lot back in the box, remebering to fi tthe fifth gear thrust washer on its shaft
i did it upside down so it wouldnt fall off the shaft either!
job done, just waiting for the turret to dry before i fit that too!
quite glad to get that all done after yesterdays saga i can tell you! should now have no crunching into second either!
not as bad a job as it looks or sounds either, although if you have no previous experience i can see it being fairly daunting
Brian is edging closer to spraying, kurrust time at the mo!
