5 Speed gearbox reassembly help (gearbox guru needed!)
 

A cracked speedo sensor from a TY752VB3FA gearbox i managed to punch down the actual speedometer shaft into the bottom of the gearbox.

I decided to swap half the casing from my old gearbox onto my new one.

I've stripped everything down, however im having some issues with dry-building (without gasket) my centre diff and output shaft.

According to these diagrams, i only need 1 thrust washer sitting in the transfer housing outer casing going to output propshaft.

However, all the documentation on the net shows that there is a washer sitting on the centre diff, but the centre diff also looks different, as if there is a phase 1 and 1.5 centre differential.

in terms of splitting the actual case, i only took off two of the ball bearing mounting bolts for the output shaft, thereby allowing me to take off half the casing, but keep all the gears in place. my question regarding this is, would i have to adjust the backlash/preload? i mean i didn't touch the ring and pinion/front differential.

also on trying to dry-install my centre diff back into the transfer case housing, i cant seem to get the spline to slide all the way in the diff whilst the propshaft gear is installed. i can do it whilst that particular gear is removed. if i gear the gears meshed into place and try and slide the spline onto the centre differential the bearing on the propshaft gear spline hits on the centre differential and i cant slide it on.

On all the youtube videos with the phase 1.5 diff, the assembly just slides on like butter.

Also, if anyone knows a place where i could drop the half split gearbox off for reassembly and wont kill me on the labour (<£100 ideally around £50) that would also be greatly appreciated

1. Buy rights yes you should adjust preload.


2. They can be a pain in the arse to get the splines to slip in.


Can you not just take your new drive out and put it in your old casing or is it stuck ?

would i still have to adjust preload if i haven't even touched the centre diff/ring pinion/ left half of the casing.

literally only replacing the side of the casing which houses the speedo sensor shaft

By rights yes its a fiddly job but not difficult. Change the drive.

is there any sort of write up on how to do the adjustment.

What do you mean by change the drive ?

I watched this video and i just have to copy the steps right.

i stress again that the case half that the ring and pinion sit in has not been touched.

You can see the pic above of the case half, im only swapping half.

if i swapped the speedo shaft from the donor case to original case and tapped the thread for the speed sensor, i would get away without the adjustment right?

as the zero contact point would be the same and therefore the backlash ?

Have you stripped the thread in your old case or can you not get it out. There is a service manual download for the box somewhere. You shouldn't be far away as its only that side of the box you have removed but you should check your preload to be sure.

No ive not stripped the thread as of yet, i just have chunks of plastic which ill need to pick out.

What i screwed up was, while i was chiselling the plastic bits out, i punched the speedo shaft out and into the bottom of the gearbox housing.

according to that video, if i use the original casings, and ive not removed the output shaft, i can techically put everything together and the preload and backlash would be correct.

Plenty of plus gas let it soak then with a ring spanner wiggle back and forth if it shows no sign of moving resort to plan A as it will disintegrate if abused.

Yes, i didnt take my time and cracked the sensor. I almost fully chiselled it out but then i knocked the speedo shaft down being 2 hard with the hammer.

Ive learmt the hardway!

Is yours a 95 car is it cable driven.

No its a 97.
I blew the uk box and threw and vb3fa and 4.11 diff in, didnt break the sensor then, because i used my brain and cut the wire and slid on a nice big socket.

This time i was moronic and inpatient, didnt think it through and now im at this predicament.

jay, if i chisel the remaning plastic sensor out the threads, resecure the speedo sensor in the shaft and use the orginial half, would the backlash and preload be unchanged ?

Yes that would be ok but is it cable driven or electrical as 97 is changeover year between v3 cable driven and v4 electrically driven.

Yes mate its electrical with the white dials its actually a v4 i believe.
cool, ill work or trying to salvage the Orginial housing.

Everything is assembled per the factory instructions.

Didnt set any backlash.

gonma throw it back in the car tomorrow and see if she works.

Ill update u and thanks for the help

:thumb: Good man half an hour tomorrow and you'll be right.