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| Joined: | 12-29-2022 |
| Location: | Melbourne, Australia |
| Posts: | 6 |
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By placing two steel flats between the front of the casing and the back of the 1st gear cog, then applying some heat, a brass hammer drifted the shaft through the gear. One gearbox in pieces! But in hindsight, I reckoned the mainshaft didn't need to be removed - the layshaft just had to be lowered.
I had another 4-speed, so I attacked it. I used a 19mm diameter timber dowel, 167mm long, as the dummy shaft for the layshaft. It was a loose running fit through the casing. 167mm was the distance between the two thrust washers, 52 and 53. Using a 3mm screw in one end of the dowel, set off-centre by about 5mm, I drifted the layshaft out so the dowel occupied the space between the thrust washers. Then another offset screw went into the dowel at the other end, and the layshaft dropped down by about 10mm onto the screws, taking the rollers and abutment rings, 51, with it. Everything was contained, hanging on the screws, and free of the primary.
Pulled the cover and primary out, replaced the seal, and refitted the primary into the cover. Refitting the assembly was dead simple - once the rollers and collar of the primary were greased up, the cover assembly was bolted in place. Then by tipping the the box upside down, the layshaft just fell back into place. The layshaft itself took a minute or so to fit, to get the thrust washers in line, and with a bit of heat on the rear of the casting, the shaft just slid in. It was really satisfying that it worked, and it saved several hours (and a lot of angst!) in the process.
Bob