Swapped shims about and got the DTI back on...
The other layshaft shims added too much drag, so sticking with the first one.
The other mainshaft shim showed 0.05mm of end play, so sticking with the other one.
Started to reassemble:
First job was to fit the end plate to the casing, also locktited the layshaft race in and fitted the oil seal:
Next the selector shaft was reassembled as per the overhaul manual, 1st/2nd fork onto the shaft with the pin located in the jaw of the fork, then the selector spool is slid on and 3rd/4th located in the jaw of the 3rd/4th fork, finally 3rd/4th&spool are slid over the pin on the shaft:
Next the mainshaft & selector assembly are lowered onto the centre plate:
Then the layshaft is fitted - the mainshaft has to be lifted slightly to allow this:
Then the pinion and 4th gear baulk ring can be fitted, layshaft has to be tilted out of mesh slightly to allow this (photo is a bit blurry, sorry!):
The maincase can now be lowered on:
If the selector has been assembled correctly the spool should be visible through the spool retainer hole:
Flip the assembly, whip the centre plate back off, apply sealant and locktite:
Fit the inner detent spring and ball bearing, I greased it up so it wouldn't fall out:
Then use some slave bolts to fasten the centre plate down:
I then test fitted the extension case gears, fifth & reverse - I didn't fit the reverse retaining circlip at this point:
I also fitted the selector ball housing, and although I can easily select between 4th and reverse, I can't engage any other gear
I suspect the spool for 1/2 3/4 is the wrong way round - does this sound about right James?
