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calling all gearbox gurus - a new one on me

To: "CARS nass@yahoogroups." <nass@yahoogroups.com>
Subject: calling all gearbox gurus - a new one on me
From: <ptegler@cablespeed.com>
Date: Sat, 26 Mar 2005 19:27:11 -0500
Now this is a new one on me.  I've rebuilt at least 15 Spit 
and GT6 gearboxes now, both single and 3-rail, with and 
without O/D.  But I've never run into this one before.

I just finished replacing the mainshaft and input shafts with
brand new oem units in a 3-rail o/d box. The tip bearing had 
worn a nice groove in the mainshaft end and the box was rather 
noisy. 2nd gear was also a bit 'chunky' when downshifting from 
3rd to 2nd.

Now I be damned if second isn't WORSE than it was originally.
But overall the shifting is smoother and the gearbox itself is 10 
times quieter that it was before.

2nd is now so bad I can not down shift to it at all even after 
double clutching. So yes it's coming back out this evening.

THE QUESTION:    
I've never really noticed this before, but is the 1st/2nd gear 
selector suppose to have enough freeplay to slide back and forth
freely on the shaft?  I've looked at all the thrust washers, clips
and etc and everything is in place and fits well.  It's just the 
selector hub that has about 1/8"-3/16 (more?) of freeplay to 
allow it to slip back and forth on the shaft .  Now I suppose this 
is to make sure both synchros are disengaged for reverse.
Am I right in assuming this is the reason for the freeplay?
I have to believe a bit of binding here (hub to shaft) is what's
stopping the hub from forcing the synchro against second gear
before the hub slips to engage to gear.

Any one have any ideas? Did I simply mess this one up?
...ways to adjust this freeplay? how easy should the hub
slide on the shaft?

tia

Paul Tegler
ptegler@cablespeed.com
www.teglerizer.com





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