On Thu, 7 Aug 2003, Mark Creamer wrote:
> 6-Packers,
Hi.
> I received a couple of good suggestions to try (thanks Bill and Greg),
> but no luck so far. I'm trying to get the reassembled countershaft
> cluster back where it belongs in the bottom of the gearbox. It will not
> go in, despite my best efforts.
Been there, done that, got the t-shirt.
> I'm wondering if there is a safe way to just slightly expand the
> internal dimension of the gearbox, just enough to get it in, and if so,
> will it then return to normal afterwards. I fear there's not much
> elasticity in the aluminum, but I'm no metallurgist.
DO NOT CHANGE ANY INTERNAL DIMENSIONS.
> Or if anyone has any other tricks, I'm all ears.
I guess the answer to your question really depends on a lot of factors. If
you would like some off-list suggestions, fire away.
I will point out two fairly easy ones. Make sure that the thrust washers
have not spun in place. If the tabs rotate just a bit, the end-float
changes to critically small and the gear cluster will hang up on them.
This moves the washers ever-so-slightly and you can't get the shaft in at
all (if the small one slips) or you can get the shaft in almost all the
way (if the big one slips).
If you can get the shaft only half-way in before things bind up, make sure
that the countershat third gear is installed correctly. I have done this
myself several times. It's been a couple of years since I built a gearbox,
but I believe that the second and third countershaft gears should butt
against each other. If there's a space between them, then third is
installed incorrectly.
> Thanks!
>
> Mark Creamer
> 6-PACK Membership Secretary
regards,
rml
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