also a pin fell out near the front driveshafts when i turned the box over to have a look at something, its about 4-5cm long and solid, where the hell does this go?

 

erm, ill have a look in the morn to see where that shaft goes, as the box is split in the shed.
which gear do you need, ill just send you my shaft with the gears on, its mint, but you'll have to swap the knackered gear over

is the knackered cog on the shaft that DOESNT go to the diff?

 

hey, mail me those piccies mate

 

here's one to be going on with

 

to the left of that picture is the rest of the box housing, can i remove it? can i.......

 

is the gear on the other shaft ok?

ill pull that gear off my shaft if you like and send it up? i want to keep the shaft itself so that i have a full diff kit (mines v.low ratio at the mo).

 

is it the back end of the box that you cant get off?

 

the other gear's perfect

i was hoping that i could fix my syncromesh at the same time but can't seem work out what has failed

 

can you make this out?

there's 3 parts to the gearbox, got the first section off, just the last 2 i can't (i was getting tired though)

 

the arrow's pointing to the casing, not a specific area

 

is this anything to do with it, it's looking through the inspection cover on the top of the box (might be the limited slip in there aswell)

 

yeah that piece with the blue arrow is the back end section. theres a cover (square i think) on their somewhere. if you remove it (only small bolts) there is a small arm on the selector shaft. this is what is stopping you. just slacken the nut on it and turn the small arm a bit, then waggle the whole lot and it'll come off.

**be sure to mark the exact position of that little arm, as it will need to go back perfectly aligned, and its not on a spline or anything either, which makes it worse!

 

beat you to it any idea where that pin came from i was on about?

 

you got there first!
think thats the one yes, hard to make it out though with it being on a piccy

it should just be about 50mm long ish

 

it's the rod that comes from the gear lever linkage


kev 500 posts

 

not sure about that other pin, will look at my box in the shed tomorrow and see whats what.

yeah, that arm is stopping another bit turning enough to separate the housings.

just slacken, then try and yank the housing off, it worked for me

 

yeah it comes from the gear linkage, but like i said, make sure it goes back exact and you'll be fine

ian......more posts than kev

 

back to the snycromesh - which one is for second & first?

red, blue or yellow?

is it the rings that wear or the splines on the cogs? sorry for all the questions, just picking your brains

 

to be honest, i havent a clue about the syncromesh (which one for which gear etc).

i would say that for first and second, then the blue arrow, and the other two to the right of it
where the blue arrow is, thats second gear you see, and then first is (obviously) the one one with the lost tooth

off to bed now mate, eyes are closing after last night

ill let you know tomorrow about that other shaft

 

sorry, that one with the blue arrow is reverse (straight cut), the one next to the yellow arrow is 2nd

yep, definately gotta go to bed

 

me too, gearboxes are heavy [img]images/smilies/mad.gif[/img]

 

i was tired last night, got this syncromesh thing sorted now



reverse has no syncromesh


kev

 

found where that pin goes aswell, first bearing on the input shaft

 

ian, did you have any luck removing that gear?

 

Check out my site, I have an exploded view of that gearbox. I have just rebuilt my own box also.

http://www.geocities.com/subman2001nz/

 

hi mate, cant shift it at the moment, may have to go and heat up the big nut to shift it

ian

 

sorry i haven't replied, trouble with my ISP (NTHell )

do you mean the nut on the end with the tab knocked in? i had i quick go at it the other day but couldn't stop the shaft spinning


kev
off to reply to one of your other threads

 

ah no worries mate, bloody computers eh!

ill have to take the shaft to work on sat and sort it, sorry its taking so long mate

cheers, ian

 

riding the motorbike to work is proving interesting could do without the rain mind


kev

 

are we any closer to getting the cog off?


kev; not wanting to rush/hassle you