Right ho, we had a misunderstanding. I thought that the input shaft finished inside the bellhousing by 10mm, not out as you've shown it, but that's OK, and it doesn't affect your problem..

Taking the figures above, your input shaft is not causing the problem, there is a 9mm void left when the two flanges meet.

Trying the Ashcroft suggestion of grease will either work, or at least show you where the clutch is getting to on the splines because of the witness mark it will leave.

Failing that, have you any means of measuring the ID of the spigot bush and spigot accurately? Just wondering if it needs reaming?
 
Not relevant but don't see why you can't select gears with only the stub? Mine works just fine and its a knackered old box.
 
So I need to measure the outer face of the cover plate to the outer face of the friction plate.. Is that the thinking?
 
It's the spigot (that's the input shaft, yes?) Is the right length overall, I was just worried about the splines bottoming out before the tip of the shaft bottoms out... As the splines will bottom out at the friction plate drive flange, and I don't have a measurement for that
 
I should add - that assumes that the spigot bush diameter is large enough all the way down to near the end.
 
It's 35mm from the straight edge across the cover plate, to the buldge on the friction plate drive flange (so it's a bit further to the start of the splines)
 
farmershort said:
It's the spigot (that's the input shaft, yes?) Is the right length overall, I was just worried about the splines bottoming out before the tip of the shaft bottoms out... As the splines will bottom out at the friction plate drive flange, and I don't have a measurement for that
Click to expand...
they can and a very common problem with td5s as people fit clutch plate the wrong way round and boss then jams against the shaft as the splines run out
 
Hold on.. Just done the maths..

There's 95mm of gap to take up, but actually we need to remove the 35mm from this, as from the shafts point of view, it's thin air... This measured across the face of the cover plate at the high points.

So 60mm of gap to take up, and 79mm of shaft... So it's not running out of shaft.
 
Front face for you James:

20160316_183718.jpg
20160316_183604.jpg
 
farmershort said:
There's no gear stick or assembly, just the very base of the shifter on the top of the gearbox... Ive tried selecting a gear with it and it doesn't work... Only goes so far... And I'm too scared of damaging it.

I have turned the flywheel from underneath with it bolted in the 5mm gap position, and the crane providing forward thrust, but it makes no odds... At a 5mm gap, the splines should be lined up OK.
Click to expand...
you wont hurt it just feel were it starts to go back or forward by rocking selector shaft then give it a sharp knock ie hammer shaft
 
You must log in or register to reply here.

Similar threads

proto57
Freelander 2 (LR2) Baffling (to me!) front Half-shaft/Axle Length Mystery! Too short, twice???
Replies
10
Views
876
Zorro587
Zorro587
T
Hello to everyone! Help me choose
2
Replies
35
Views
4K
Mark Piercy
Mark Piercy
Maat
Disco 1 R380 output shaft wear question
Replies
1
Views
1K
tottot
tottot
Stev
suspension in extended mode and Suspension failure
2 3 4
Replies
68
Views
6K
Stev
Stev
D
Half shaft install help!
Replies
11
Views
2K
Bearhound
B