Cheers, so it is, wierd thing is the one's I took apart the plastic bit was transparent and seemed thinner.
 
Cracked on with cleaning up the casing in the lovely sunshine!

Wire brushed down & masked up:
IMG_20140518_142908.jpg


Zinc primer 1st coat:
IMG_20140518_143906.jpg


Matt black 1st coat:
IMG_20140518_145841.jpg
 
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.

IMG_20140518_203105.jpg
 
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.

IMG_20140518_214806.jpg
 
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).
 
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
 
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.
 
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
 

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