Baron von Marlon
Member
I was really pleased with myself - I've rebuilt the main part of the LT77 box with no problems, right up to now, where I try to fit the 5th gear and selector mechanism to the rear of the mainshaft. When I put all of the components together and fit them, there is insufficient room for the circlip to be fitted.
The location of the parts is decided by the position of a circlip, which is to the rear of the bearing that runs in the centre plate. This is new, and in the correct position:
On top of this there is a spacer, which I didn't photograph, but I know it's the right one as this whole assembly was cable-tied together on removal. The 5th gear then fits on top of this spacer, with needle bearings inside it:
This sits nicely on top of the spacer. Then, on top of the gear goes the parts below, in the following order:
Baulk Ring
Sychro Hub
Support Plate
Selective Washer
These parts will only fit one way and again, all slide down the shaft nicely until all are tight against each other. Unfortunately, when everything is in position, the gap isn't anywhere near large enough to fit the circlip properly in its groove:
I'm starting to think that it was never fitted properly in the first place - unfortunately I started stripping the box a good 6 weeks ago, so have forgotten exactly what everything looked like! I did take an overall picture of the that end of the box with the cover off, but I can't really make out if the circlip was fitted properly, or not. This is a zoomed in crop of that picture, but I can't make my mind up.
The smallest selective washer, if it were actually available, is 5.10mm deep, so would only give an extra 0.3mm over what's already fitted, which still isn't enough to get the circlip in the groove properly.
I guess my only option is to machine down the spacer - does anyone have any other thoughts, please?
The location of the parts is decided by the position of a circlip, which is to the rear of the bearing that runs in the centre plate. This is new, and in the correct position:
On top of this there is a spacer, which I didn't photograph, but I know it's the right one as this whole assembly was cable-tied together on removal. The 5th gear then fits on top of this spacer, with needle bearings inside it:
This sits nicely on top of the spacer. Then, on top of the gear goes the parts below, in the following order:
Baulk Ring
Sychro Hub
Support Plate
Selective Washer
These parts will only fit one way and again, all slide down the shaft nicely until all are tight against each other. Unfortunately, when everything is in position, the gap isn't anywhere near large enough to fit the circlip properly in its groove:
I'm starting to think that it was never fitted properly in the first place - unfortunately I started stripping the box a good 6 weeks ago, so have forgotten exactly what everything looked like! I did take an overall picture of the that end of the box with the cover off, but I can't really make out if the circlip was fitted properly, or not. This is a zoomed in crop of that picture, but I can't make my mind up.
The smallest selective washer, if it were actually available, is 5.10mm deep, so would only give an extra 0.3mm over what's already fitted, which still isn't enough to get the circlip in the groove properly.
I guess my only option is to machine down the spacer - does anyone have any other thoughts, please?