Shift forks set up trouble

osvaldo

New Member
Good morning,
I am italian, excuse me for my poor English

a bit of introduction:
I am busy overhauling my gearbox from a 1973 2000 TC.
This is a roller cages gear bearings type, so I think the last issued.
I removed and opened the box because the output shaft get broken at the thread fixing the output flange.
Not a fault of the car but of the 'killer' that had 'mis-fixed' the flange in a way that even the oil seal was not working. Unbelievable.
I got the shaft end flat and made an inch deep 3/8 UNF female thread and I am going to use the highest grade bolt.
Apart of that I replaced few things: front countershaft bearing, 4th gear synchro, output oil seal and flange.
So said, while I am waiting for the right manual, I am using a bronze bushing type manual as a guide.
Setting up forks position as for that manual specs, it does not seems to get a reasonable result (really too much over travel on the other side that could means you don't engage well the gear)
I have not performed the drag force test to get the gear out as I am working alone and is not easy to feel it right.
In the while there are few things getting me thinking about:
Are roller cage type spec different?
My bronze fork little shoes are a bit worn: are you aware of any factory specs for shoes/outer rings clearance limits? Mine is around 20 ths.
Have you got any tricks to keep shafts standing while tightening fork bolts?

I try a different way: with outer ring in the middle position kept by spring/balls to put forks/shoes as well in the middle of ring grove, but I got a very asymmetrical over travel when put in gears. I can't realize why.

Any help will be enjoyed

Best regards

Osvaldo
 
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