Post by madmax on Jul 5, 2011 15:50:41 GMT
right then here is my gearbox, ignore the fact i have a pk 1st in a primmy gearbox
here it is out and built up
now with just 1st on raised part up
now put the selector into neutral and put 2nd gear on top raised part facing up, and make sure both spin freely
next, put the gear selector into second and make sure the lugs are flush with the gear indents
if not flush then a thicker or thinner shim might be needed on the bottom, under 1st gear, the selector is thicker than the indent so you have a little leeway
next move the selector up into 3rd and then pull it down so it sits on the gear indent
like this
then leaving it there and still pulled down fit 3rd gear, raised part up and make sure that it spins freely and doesnt hit the selector.
next, select 3rd gear and make sure the selector is flush again
then select 4th pull down and sit the selector on the gear indent again
fit 4th raised part up, indents flush with machined part of gear
this too should spin freely without hitting the selector
select 4th, the selector may well sit proud of the 4th gear indent but when you have the shim/s and circlip fitted this prevents that
assuming all is ok you can now shim the top end of the box, ive done mine to 0.1mm
hope this helps
if any of the gears are the wrong way it won have a false neutral between them and will select 2 gears at once, this is why we drop the selector onto the indent and fit the next as if it doesnt spin its wrong
you will notice that the gear indents do not sit central to the cog and that they are offset
first gear the offset needs to be at the bottom like this
second gear the offset is at the top like this
3rd the offset is top
and 4th is also the same
if all is ok when you spin it up with my method in the first lot then it should be ok, and get plenty of grease on the seals when you put it together
Thanks jonnyss.