KTRIUMPH@aol.com wrote:
> In a message dated 12/28/99 10:55:33 PM Eastern Standard Time,
> wdaehler@execpc.com writes:
>
> << My TR4 clutch rebuild project was going great. I replaced the three
> needle bearings and re-installed the 3rd gear C-clip. These were hard
> jobs. Having got this far I hadn't ever read from the discussions on the
> list I wasn't prepared for any insurmountable hurdles after this.
>
> But I am at a major impass. With everything in the gear box I have
> about 1/4" gap between the rear main bearing C-clip and the wall of the
> box.
> If I push and pound, the whole assembly slides and I get the same 1/4"
> gap between the C-clip on the front main bearing and the wall of the
> box.
>
> I've looked and double checked everything, and it looks like the culprit
> are the replacement brass syncro rings. The don't seat against their
> mating gear as closely as the old ones I replaced.
>
> OK, maybe I shouldn't have replaced the synchros, but the Bentley said
> that it would be "false economy not to do so".
>
> Who's had this problem? Is the solution to tear everything down
> again,and put back the old synchros? Am I being stubborn just because
> the four new synchros was a major fortune?
>
> Please help.
>
>
> Will in Wisconsin
> 64 TR4
> >>
> Hi Will
> Pull the input & mainshafts back out and double check all the dimensions.
> Sounds to me like you maybe have one of the synchro cups on backwards, or
> perhaps there is something fouling the input - mainshaft juncture? The OA
> dimension for the mainshaft assy is given in the workshop manual. If you
> don't have, I can scan it for you.
> When properly installed I believe the synchro rings are rather loose, so they
> would have to be WAY off to cause this situation.
> BTW Have you installed the small C-clips on the shafts that hold on the main
> brgs? If the assy is wrong on the mshaft you may not clear the groove where
> this animal sits. If not then almost surely something is amiss in the
> mainshaft assy. Good Luck!
>
> Ken Nuelle
> 58 TR3A
> 62 TR3B
> 64 TR4
Will,
I agree with Ken. Look carefully at the 4th gear syncro. It has three teeth
that fit
into corresponding recesses in the 3-4 hub. If the syncro isn't oriented to
drop into
into the hub recesses, it will make the entire assembly about 1/4" too long.
All the
others would have to be right or you couldn't have gotten as far as you have,
so check
that 4th gear syncro (the forward-most one between the input shaft and
mainshaft).
Regards,
Brian Schlorff '61 TR-4 '64 TR-4 '72 TR-6 '79 Spit
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