19-12-2018, 08:48 PM
I got the gears in last night then found it had all locked up. I ended up re-shimming under the layshaft bush and very carefully selecting the right paper gasket thickness and testing it all with the layshaft bolted in properly. That's where I had gone wrong, my initial attempts were based on measuring with things not done up fully. It's surprising how much things change when done up tight. I got the layshaft endfloat to 4 thou in the end.
I also had one of those SPROINGGGGGG! moments when I pushed the 1/2nd gear synchro a tad too far and everything came apart. I found to get the gears in you need the 1/2nd synchro in the second gear engaged position. Luckily I found all the balls so no harm done. After that it all went together pretty easily with a bit of heat from the heat gun.
The selectors aren't in yet (tonights job) but it all looks good so far. I enjoy seeing how something like this goes together and understanding how it all works. I put tape on the input and output shafts so I could see how the ratios change. Especially things like seeing why you shouldn't ever drive with your hand resting on the lever. It's good to be told things like that but even better to see and understand why yourself.
I also had one of those SPROINGGGGGG! moments when I pushed the 1/2nd gear synchro a tad too far and everything came apart. I found to get the gears in you need the 1/2nd synchro in the second gear engaged position. Luckily I found all the balls so no harm done. After that it all went together pretty easily with a bit of heat from the heat gun.
The selectors aren't in yet (tonights job) but it all looks good so far. I enjoy seeing how something like this goes together and understanding how it all works. I put tape on the input and output shafts so I could see how the ratios change. Especially things like seeing why you shouldn't ever drive with your hand resting on the lever. It's good to be told things like that but even better to see and understand why yourself.