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Jun 27, 2011 8:03 pm
Jun 27, 2011 8:03 pm
Subject: Re: G9 gearbox
Just a final word on the G9 if anyone else is tempted to rebuild theirs. Mine is now back together but I have only done one short trip so far. Everything works fine but only time will tell !
However, I cannot stress how important I think it is to clean out the oilways in the gears. I dont think there is much point in rebuilding the gearbox if you do not do this. Second gear is quite easy once you have pushed the bush out. However 3rd and 4th are much more of a challenge as the actual double helical gear itself must be pushed off the steel syncro "housing" (for want of a better word). Each gear is on 2 keyways and you will need 2 hardened steel pins to assist in pushing it off (and a hydraulic press). This was very very difficult but it is only by getting the gears off that you can properly clean out the oil holes and tracks. 3rd gear bush relies on the oil getting through as otherwise it will seize on the mainshaft presumably. Just as importantly the oil ways in 4th gear allow oil to get through to the little bush on the nose of the output shaft and inside the input shaft.
Best of luck to anyone else who decides to have a go !
Just a final word on the G9 if anyone else is tempted to rebuild theirs. Mine is now back together but I have only done one short trip so far. Everything works fine but only time will tell !
However, I cannot stress how important I think it is to clean out the oilways in the gears. I dont think there is much point in rebuilding the gearbox if you do not do this. Second gear is quite easy once you have pushed the bush out. However 3rd and 4th are much more of a challenge as the actual double helical gear itself must be pushed off the steel syncro "housing" (for want of a better word). Each gear is on 2 keyways and you will need 2 hardened steel pins to assist in pushing it off (and a hydraulic press). This was very very difficult but it is only by getting the gears off that you can properly clean out the oil holes and tracks. 3rd gear bush relies on the oil getting through as otherwise it will seize on the mainshaft presumably. Just as importantly the oil ways in 4th gear allow oil to get through to the little bush on the nose of the output shaft and inside the input shaft.
Best of luck to anyone else who decides to have a go !