LT230 rebuild

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Ta James.

When I'm test fitting the main and layshaft to check the end float, should I just seal and loctite the front housing plate and outer races in or fit loose? Guessing loose because I'll need to fit the input seal last?
 
dry fit till both shafts are correct ie no freeplay and slight preload( 2 thou )but no free play but turn easy is good then loctite all bearing races and shims
 
Sorry to be a numpty, but I don't know what you mean by 2 thou preload, how do I measure that?

I was just going to go by the endfloat DTI values the rebuild manual states.
 
endfloat isnt what you want whatevers written in maual,but you start with endfloat and measure and shim accordingly ie 10 endfloat requires 12 thou thinner shim to give 2 thou preload,but usuall if you use original shims and theres no freeplay and shafts dont have drag its good
 
IMG_20140506_135026.jpg


Just need to sack the bikes off into another shed now...
 
Catastrophe time :(

Decided to try out the press by fitting the reverse idler to the centre plate, didn't notice until too late that for some reason the press plate was not flush with the bed??

Resulting in this:
IMG_20140506_154551.jpg


The shaft went in suddenly with a bang and popped off part of the centre plate :(

I can push the shaft part way out with just finger strength - guessing that's the casing knackered then.

IMG_20140506_154603.jpg


Really not happy with myself.
 
OK, well I've figured out my schoolboy error.

The shed floor isn't even.

So the base plate was leaning to one side, whereas the pressure plate which hangs on springs was level == wonky pressure applied.

I've levelled it up and it's now fine.

DOH what a retard!
 
Started work cleaning up the other case....

Gunked, jetwashed, front cover removed, naff reverse idler pressed out and splash plate removed.

Needs attacking with the wire brush then it's getting painted.

IMG_20140506_182417.jpg


Also fished out the centre bearing shims that go with this plate.
 
Awww no that sucks massively I did a similar thing but managed to ruin the bearing. I was doing fortunately they weren't expensive atall but it will be something's you never do again trust me it will be check once check twice then check with each pump lol make sure it's all square makes ife so easy lo good for stratening bent bars aswell :)
 
Been a bit stalled on this due to having to sort out my exhaust manifold and the wet weather (can't paint the case indoors), hopefully should crack on this weekend and make some good progress.
 
Cleaned up the 5th/reverse gears & hub assembly, replaced the springs and baulk rings - no idea why I cleaned up the 5th gear because I'm replacing that one with a V8 ratio one, DOH!
IMG_20140516_181825.jpg


Cleaned the oil pump assembly and fitted a new gasket. O-ring will be replaced when I fit the pump.
IMG_20140516_181834.jpg


Next job, will be case painting a little later this evening.

Then tomorrow it's on to pressing bearings in/on and checking preload.
 
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