405 Gearbox Rebuild and Clutch Change

evilally · Unread post by **evilally** » 19 May 2010, 10:29

I'll see if I can get it whipped back out tonight. I'll double check everything, but what I might do is transplant the hub from the new shaft onto my original one. That will rule out any defect or differences, and it will eliminate the possibility of me getting the preload wrong.

Clutch feels great!

Unread post by **CitroJim** » 19 May 2010, 10:35

Jolly Good Ally...

Pleased you have a good, robust attitude to this

I'm going to study preload a bit. I have a gash BE3 here...

Where are you located? If you're not a million miles away from me or en-route to one of my frequently visited places, I might be able to cast an eye...

evilally · Unread post by **evilally** » 19 May 2010, 11:18

Don't worry....it WILL get fixed

The second time round should be a fraction of the time, everything's all clean and I know what I'm doing.

That's a very kind offer, but I'm near Glasgow, which I suspect is not very handy?

Unread post by **CitroJim** » 19 May 2010, 12:21

I like your attitude a lot! Good on 'yer

evilally wrote:That's a very kind offer, but I'm near Glasgow, which I suspect is not very handy?

No, it is quite a trek away

I had a belief you were in Hertfordshire somewhere..

addo · Unread post by **addo** » 19 May 2010, 12:31

Are both gearsets the same?

I thought BE3s came in a variety of ratios and the OP was only adding a replacement mainshaft.

I'd assumed also, that the gearbox had been hand rotated through all gears prior to installation.

evilally · Unread post by **evilally** » 19 May 2010, 19:45

Gearbox out in 1 hour 45 minutes.....very pleased

Off to grab a bite to eat then I'll get started on stripping it down.

Unread post by **RichardW** » 19 May 2010, 21:14

Before you strip it down, check you haven't bent the input shaft hefting the box back on - that will be an easy fix if so!

evilally · Unread post by **evilally** » 19 May 2010, 21:35

Too late, it's stripped down! I didn't notice it bent, but I'll double check that tomorrow! I've double checked the tooth count on all gears, they're idendical. So I think the plan will be to swap the hubs, tomorrow nights task.....

evilally · Unread post by **evilally** » 20 May 2010, 19:36

Synchro cones off.....

Good hub (left), bad hub (right):

Close up worn cone, the top portion is worn smooth:

Replacement has a manufacture date stamped on it, 04/02/99!

I'm to try and figure out how to reassemble the thing now......

evilally · Unread post by **evilally** » 20 May 2010, 21:44

Ladies and gentlemen (I suspect mostly gentlemen), I present to you a super-easy way of reassembling a BE3 input shaft

A 5th gear sleeve from the spare box:

An injector deep socket:

Place the sleeve ontop of the bearing, it's a perfect fit:

Drive home the bearing as far as possible with the sleeve, then place the injector socket on top:

Then drive home the rest of the way......

The whole thing took seconds!

Gammy leg · Unread post by **Gammy leg** » 21 May 2010, 08:06

Aaaaaagh, Daily Mail!!!!!

Unread post by **CitroJim** » 21 May 2010, 08:21

Ally,

Great work!!!

If you do not work professionally as an engineer then you've missed your vocation

Gammy, it could have been worse. At least it was not the Daily Star...

Deanxm · Unread post by **Deanxm** » 21 May 2010, 09:04

Gammy leg wrote:Aaaaaagh, Daily Mail!!!!!

Its fine, its being used for its intended purpose

.
Great work Ally, nice to see someone getting stuck into a gearbox!

D

Unread post by **myglaren** » 21 May 2010, 16:35

CitroJim wrote:Ally,

Great work!!!

If you do not work professionally as an engineer then you've missed your vocation

Gammy, it could have been worse. At least it was not the Daily Star...

Hey! I used to read the Daily Star*

*OK, It was 45 years ago

evilally · Unread post by **evilally** » 21 May 2010, 18:17

Don't worry, I found it in the blue recycling bin

I found the source of the problem I think. I've noticed that the roll pin on the bottom of the reverse gear shaft is sheered off

My original is on the left, fortunately I have managed to retrieve the broken bit of metal from inside the gearbox.

The one from the doner box is a different design, but it fits perfectly. I'm not sure if I should use it or not. I could try removing the pin from it, but then I might end up with 2 knackered shafts. Opinions?