Not so merry christmas

[rosscla]

Going back to the scuffing on the case, does it rub with the clutch bell bolted up. I find that the Christmas tree is pulled up away from the rear case but scuffs it with just the backplate on.

Not sure I will check, I was wondering whether this was the cause myself as have been messing around with layshaft shim sizes a lot trying to free up the gear box once the end plate is on

Bear in mind the clutch centre will pull the Christmas tree up even if ever so slightly and can be enough to free up what feels like a stuck box when the clutch have nut is tightened.

[Snails]

True although the shim is hard to spin so my money's on that. Worryingly I'm already on the next to smallest shim.

[rosscla]

And just to check you have the hub on and tightened down and the gear stack is taller than the layshaft?

[Snails]

And just to check you have the hub on and tightened down and the gear stack is taller than the layshaft?

why do you ask?

The tree is fine once the gear box and endplate is assembled but the gear box is lockimg up whenever I fit the endplate. I'm on the smallest shim size now and its still doing it.

The gear stack is taller than the layshaft but only just. Could this be an issue?

I dont have the rear hub fitted but I have done before to ensure that the layshaft is fully home. I've also had the end plate bush that sits around the layshaft replaced and checked this twice with a local shop ensure that its all the way home. The old one apparently was not and it got damaged (a small chip at the top) when I removed the end plate on one occasion. As I've also managed to destroy two bearings (for the endplate/layshaft) so its proving quite expensive.

[wack 63]

Have you tried fitting the endplate with the cluster fitted but no loose gears, to check it's not the layshaft or oversized hub bearing?

[Snails]

No I have not. Will give that a try.

[rosscla]

I had a box that was difficult to shim without the torque on the hub (actually on a spacer but same differences). I torqued it up and it was fine. I wondered if it might not relax back a bit with no pull on the shaft.

As long as it's taller you should be able to shim it, if it's even or the layshaft is taller it will bind.

[Snails]

I've not tried the hub suggestion with every thing assembled yet but I have fitted the end plate without the loose gears and its locked solid - so good tip lloyd - this means my layshaft is not through the bearing properly? I've tightened the hub up on the shaft as much as I can in the past, so other that really wacking it with a hammer I'm not sure how else to get it to move further through, I do wonder if my layshaft is any good as its been a right bugger to pull through two separate makes rear hub bearings - even though the bearing face diameter exactly matches the one you checked for me Lloyd.

Is there anything else that could be the cause of it locking? I dont have a spare end plate to swap over unfortunately

[HxPaul]

Fit the christmas tree in the endplate,remove the layshaft from the engine case,replace the endplate and christmas tree,Tighten the endplate and fit the clutch spider,tighten the spider and see if it will spin freely.