Let Down Gently - T5WC for sale?

[ukkid35]

Andy_mr2sc said:

I must be lucky as my fith gear slid off the shaft after removing the snap ring and tapping the end of the shaft with a copper mallet.

Thanks - keeping my fingers crossed that will work for me.

Perhaps the fact that it had already been munched has caused it to seize on the shaft.

[ukkid35]

Even with few teeth left it's larger than the outer race.

[Supateg]

My fifth gear also slid off, very lucky or the splines are worn, only time will tell.
TVR fifth gears are bigger so it won't slide through the bearing.
W
Two options
1.pull the gear an risk chipping teeth (no such problem for you there Paul )
2. Cut the bearing outer race and buy new bearing (ok if you have a rebuild kit)
Fingers crossed the donor box fifth isn't too tight.
The picture of the fifth gear damage is what the 5speeds plate is made to resolve.

[Supateg]

Bearing grindinghttps://m.youtube.com/watch?v=piCMtiE2XEE

Neat ford tool for same problem

https://m.youtube.com/watch?v=euDLr1LNFg8

Seen a three legged puller with ground lips and longer too (video) but carnt seem to find it atm!

[ukkid35]

Thanks again for all your help and advice. The box is now on the car with the help of a very patient friend.

Here are a couple of pics to illustrate some of the problems. One of them being the very stubborn retainer plate bolts. Sometimes I just have to remember that tools can be sacrificed.

[Supateg]

Well done!

I folded over the lock tabs with a punch & luckly I have a set of Sykes Pickervant flank drive thin walled sockets that fit over the 'hex'; lower two came out with little force, upper two were tight! I can see how it would shatter the torq bit!
The 5speeds plate was quality and hopefully added insurance to fifth failure;
I noted from one of the videos Paul C grinds oil ways in the counter gear shaft for increased fifth lube.

One Question I have Paul with regards to your fifth gear failure?


The plate retains the pre load(or zero end play as std) on the countershaft and supports the outer bearing race. The countershaft bearing is tapered so when the tolerance is lost the distance between the gears (mesh) increased hench stripped teeth.

Or lubrication is lost under the counter gear fifth with much the same effect as above.

In your opinion what happened with your fifth gear?

Ta

[ukkid35]

In my opinion it was mainly due to play in the output shaft, as the lateral movement of the input shaft was quite significant when I had the box out for a clutch change two years ago. There didn't seem to be much movement of the countershaft. However I still think it very worthwhile fitting the stabiliser.

This is my only experience of gearboxes, I've never had to touch one before.

[ukkid35]

The T5WC has just completed a 1000 mile round trip to the Ring, sadly the trackday itself was cancelled due to fog.

The car does seem to make some weird noises that I'm sure weren't there before, but I can't be absolutely sure it's the box.

I was quite anxious on the way there, hearing various noises thinking that my amateurish attempt to set the countershaft pre-load might have cost me another gearbox, but it seems to have survived. All gearchanges are crisp and smooth (better than the old box), so I'm guessing all is well.

Now I have time to consider what to do with the old box.

[Jhonno]

That's a bugger.. Nice run to check it works though!

Possibly a bit confused.. Did you rebuild your box in the end or a new one?

[ukkid35]

Jhonno said:

That's a bugger.. Nice run to check it works though!

Possibly a bit confused.. Did you rebuild your box in the end or a new one?

Practiced taking apart the old box, which is where the pics are from, then fitted the 5th gear billet plate in a used box I bought off a fellow PHer for a very good price. The old one is awaiting its ultimate fate.

[LongBaz463BHP]

http://www.pistonheads.com/gassing/topic.asp?h=0&a...

[ukkid35]

So the replacement gearbox lasted about 5k miles, although some of that was track miles. The failure is to the input shaft, which according to some YT videos is not uncommon.



However the really sad part is the damage to the countershaft



I have a perfectly useable input shaft from my 5th gear failure box, and what I'd like to know is how long a Frankenstein box like this would last, if I just swapped input shafts.

I'm not asking simply because I'm too lazy to rebuild the box properly (in part but not really), it's because I have DN15 booked in a few days time and I'd really like to be there if possible.

If it could survive 1000 miles, 800 highway and 200 on track that be wonderful, but is that too much to ask?

Assuming it fails, now I've had more time to think about the failure mode, I reckon as long as I can select 4th, I should be able to drive an unlimited distance. Or at least far enough to be able to get home.

Any thoughts?

[gruffalo]

I guess that will depend on the wear patterns on the various second hand parts that have not been worn against each other if that makes sense.

If you build the box back up from bits you have it will get you infinitely further down the road than your old box but that may only be 10 miles or 1000.

You could probably do a contact test on the gears, it will give you an idea of how big a mismatch there is in wear.

This is why I bit the bullet and went for a full Quaif semi helical gear set after two failures in quick succession it works out cheaper in the long run.

[m4tti]

Id be tempted to send it to Readman Racing... the cost isn't as bad as you think.

[ukkid35]

m4tti said:

Id be tempted to send it to Readman Racing... the cost isn't as bad as you think.

I called Readman Racing about supplying a new input shaft - and just the part alone is £200 plus VAT.