Roadster Rebuild Diary from Cornwall

[meverett]

Re: Roadster Rebuild Diary from Cornwall

Day off work today and done my chores so get on with the gearbox. Investigation over. Gearbox fully stripped down with all the parts on the bench. I had 24 needle bearings in one side and 23 in the other side of the layshaft.
Next problem I have is the reverse gears are a bit chewed up, anyone know where I can get replacements?

IMG_3528.JPG
IMG_3529.JPG
IMG_3530.JPG

[b_caswell]

Re: Roadster Rebuild Diary from Cornwall

There isnt any type of pin to locate the thrust washer that the springs load against.

The thrust washer has a bent tag that sits in a groove in the casing, it can only move as far as any wear on the rear thrust washer. The only way the spring could have got into the bottom of the box is that it fell through the bolt hole last time the bell housing was taken off.

I think you really do need to investigate further.

[meverett]

Re: Roadster Rebuild Diary from Cornwall

Hi Ben, I didn't disturb the lay shaft, I also couldn't understand how a roller pin could come out. It could have been in there from the original assembly.
My thinking now is it could be a layshaft pin that holds the plate in position where the springs push against. With this pin out the plate has moved back slightly, enough to pull one of the springs in and chew it up.
I suppose there is only one way to find out.

[b_caswell]

Re: Roadster Rebuild Diary from Cornwall

Not sure how a needle roller could escape unless you pulled the lay shaft spindle back when taking off the rear extension. The rear extension will need to come back off even if only to allow the lay shaft spindle to slide back about an inch or so to replace the needle.
You need to use your little finger with loads of grease in the front as you pull the spindle backwards to stop dropping more needles before trying to replace the stray needle.

Best of luck with that!!

[meverett]

Re: Roadster Rebuild Diary from Cornwall

I stripped the rear extension off the gearbox to replace the gasket, done and back together. I now know where the 3rd laygear spring went, after checking I had all gears after putting it back together I saw the chewed up spring through one of the bell housing bolt holes.

IMG_3524.JPG

Whilst trying to retrieve this spring I noticed what looks like a layshaft needle roller bearing (a single needle) and I haven't even stripped it down to that extent, a few choice words as I am now thinking it will be a complete strip down to put that one needle back in.

[meverett]

Re: Roadster Rebuild Diary from Cornwall

When I said the final drive I meant the prop shaft flange on the gearbox. Gearbox is off the car with the bell housing removed and currently sitting on the work mate.
I used a piece of 3' box section and drilled two 10mm holes approx 58mm apart and bolted this to the flange then using the breaker bar and socket on the nut it gave way. That bugger was tight but got there and the flange just pulls off easy revealing another slightly perished oil seal. Now to split the gearbox from the rear extension to replace the gasket then put it all back together.

[Blue Marlin]

Re: Roadster Rebuild Diary from Cornwall

I bought a £60 impact gun and socket from fleabay and buzzed it. It came off no problem. Maybe I was just lucky.

[lil_red_roadster]

Re: Roadster Rebuild Diary from Cornwall

Or in my case, rear tub off, handbrake hard on, a foot on each rear tyre & a 4" scaffold pole over the torque wrench were sufficient to shift the nut...as Ben says the flange is easy after that

[b_caswell]

Re: Roadster Rebuild Diary from Cornwall

Assuming you have managed to get the end nut undone 150 ft/lbs the flange should come away its on splines. a small two legged puller should do it.

[meverett]

Re: Roadster Rebuild Diary from Cornwall

Good point Ben, many thanks. Just checked the bolts that I had removed and they all have spring washers so I had better look for a copper washer. When I removed the bell housing there was a fair bit of silicone that I had to clean up, as the oil seal had failed the last owner decided that was best instead of replacing the seal and gasket. I have also noticed that they misplaced one of the laygear springs as well so I have ordered one of those. I now feel the need to remove the final drive flange to replace that oil seal and while I am at it remove the rear extension to replace that gasket. Getting the final drive flange off is proving to be a challenge though.

[b_caswell]

Re: Roadster Rebuild Diary from Cornwall

In case you haven't noticed the bottom bolt in the bell housing has a copper washer and needs to go back in the bottom bolt hole.

[meverett]

Re: Roadster Rebuild Diary from Cornwall

Ok thanks will wait. I have a set of adjustable tie rods that I am going to clean up and replace the standard ones as well.
As for a panhard rod in my other thread, do they help, would the RTL linkage be better? That looks a neat solution to the sideways movement of the back end. Has anyone fabricated one at home?

[dcunn]

Re: Roadster Rebuild Diary from Cornwall

Suggest as Andy says you wait a while. May even be better to wait until its all together then get in and and bounce it around a bit

[andyf]

Re: Roadster Rebuild Diary from Cornwall

I wouldn't worry until you put the engine and box in as it will settle down then.

[meverett]

Re: Roadster Rebuild Diary from Cornwall

Been stripping the bell housing off the gearbox today to clean up ready to paint. The first motion shaft oil seal was perished and gasket fell to bits so ordered a new set. Put the build wheels on and noticed I have got a camber issue as in the picture. I haven't taken any measurements yet other than one side is sitting 5 mm higher on the damper (centre to centre of mounting bolts) even though I set the outer ends of the suspension arms 150mm lower than the inner mounting so some minor adjustments to be made.

00061.JPG