jamesmartin · May 16, 2014

you know the synchro springs should be staggered ie gap not in same position on both sides

Bennehboy · May 16, 2014

jamesmartin said:
you know the synchro springs should be staggered ie gap not in same position on both sides

Yep done that mate, but ta for pointing it out.

Bennehboy · May 16, 2014

I've got a horrible feeling the oil pump gasket needs the backing peeling off - any idea on this James?

Bennehboy · May 16, 2014

Bollocks, out of masking tape - no painting tonight.

Beer'o'clock

jamesmartin · May 16, 2014

its a plastic type gasket

Bennehboy · May 16, 2014

Cheers, so it is, wierd thing is the one's I took apart the plastic bit was transparent and seemed thinner.

MudM8s · May 16, 2014

Is this all a hobby Bennehboy? It's on the bloody impressive side of a bit of DIY at the weekend!

Bennehboy · May 16, 2014

Yeah, keeps me out of the missus's hair.

Bennehboy · May 18, 2014

Cracked on with cleaning up the casing in the lovely sunshine!

Wire brushed down & masked up:

Zinc primer 1st coat:

Matt black 1st coat:

Bennehboy · May 18, 2014

Reverse idler pressed into centre plate.

Oil splash guard fitted.

Both bearings pressed onto the layshaft.

Checked preload with both of the shims from the 2 boxes I have to hand and there's no end float at all, medium drag - looks like I need some more shims.

Bennehboy · May 18, 2014

Pinion bearing and pilot bearing outer track fitted

Bennehboy · May 18, 2014

Centre bearing pressed onto mainshaft.

Pinion, pinion bearing track, 4/3 baulk ring, mainshaft, centre bearing track & shim assembled into casing ready for DTI'ing.

Doesn't appear to be any endfloat, but there's no drag on the bearings at all.

jamesmartin · May 18, 2014

as long as theres no end float its ok

Bennehboy · May 18, 2014

jamesmartin said:
as long as theres no end float its ok

I think I need to recheck the bearings on the layshaft to make sure they're fully pressed on - no reason to think not, but can't imagine the bearing tracks are massively different (although as already said the layshaft front bearing doesn't have the spring retainer on).

jamesmartin · May 18, 2014

they rarely do now its a few years since ive seen a new timken with the groove, dont forget to loctite shims and races in to case when final build occurs

Bennehboy · May 19, 2014

Any chance I could give you a buzz James, or vice versa - PM'd you my number.

Bennehboy · May 19, 2014

Ta for the call.

Bennehboy · May 19, 2014

Layshaft shim that's too thick is measuring up at ~1.6mm thick, not sure how much trust to put into my Chinese digital calliper though.

jamesmartin · May 19, 2014

you can get 1.45,1.5 ,1.55 smaller than your 1.6,1.6 is 5 thou bigger than 1.45 which is enough to make rotation very stiff

Bennehboy · May 19, 2014

Don't spose you know part no's?

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