Hi guys from Australia

I have ordered parts and essentially rebuilt the transmission with new synchros, 2nd gear, 2nd gear hub/sleeve, bearing and seals.

I am re-assembling and have two questions:

When I place back into the Tranny the teeth on the gears on the countershaft side are a little bit 'lower' than the teeth on the main shaft. They don't interfere as far as I can see, and the 1st gear (?) seems like its JUST clearing the Diff Final Drive.. Is this normal or should there be a reasonable space between final drive and 1st gear clearance / should all the gears line up perfectly such that top and bottom edges line up? I wonder that once I put the tranny cover on that the circlip (sp?) will hold/adjust the countershaft at the right distance? (Thus the clunk I heard when I undid it in the first place???)

Also I am having trouble measuring distances for the 72mm Shim however given that I haven't replaced anything that you put back on the shaft to meausure clearance can I also assume that the same shim will be satisfactory? Will save me a huge eff around..

Anything else I should check before sealing the case? (It seem the gears shift ok ... )

Thanks Guys!! (And God BLESS the guy who posted the awesome pic based DIY Guide .. It was only the Main Shaft but it gave me the general idea on how to figure it all out from there)..

Thanks ,, First Timer!

Ewen

 

Bump ... Anyone?

 

You should be okay reusing the same shims since you only replaced the 2nd sleeve set. The countershaft needs to be lifted into place so the clip locks in the bearing groove. The C/S is held in place from this clip in the correct position.

 

Thanks for the reply -- I figured that much as I was meticulous putting it back together but I couldn't seem to get the bloody counter shaft high enough to get the c-clip to bite onto it, and when I tightened the case down (very slightly each time of course) I couldnt get the bloody c-clip to go fall into the groove (even with 'bumping' the case upside down on the ground). Also the shaft seemed to lock itself and turning the main shaft was near on impossible...

Ended up dropping into Transmission place to put back together lol --- I learned a hell of a lot, first time rebuilding transmission and I'm sure it was only one small bloody thing that stopped it from going together properly (or a trick I don't know). I also had to use two screwdrivers to separate the clip which made life hard.

The Carbon Synchros look the goods !! Received everything from you very quickly once the payment was sorted.. Thanks!

Will update thread for search purposes when its back together detailing the difficulty.

Thanks again

 

LMAO! You're welcome, Ewen! Let us know how that trans comes out. It's normal for the CS to sit lower like that. Once you get the C-clip locked onto the CS bearing, the CS lifts up, and the gears will mate on the same axis.