Let Down Gently - T5WC for sale?

[ukkid35]

On my way to DN11 this morning, only managed to get 50 miles from home when on the M25 fifth gear disintegrates. Managed to limp home in forth (thank you), but very disappointed.

However my 225k mile 928 is far less amused as it has become the back up car for DN11, so very unfair.

Anyone one have a spare T5WC for sale?

[ukkid35]

Supateg said:

Very sorry to hear Paul.

I've just fitted the 5Speeds counter gear plate. I have Paul Cangialosi's book which helped.
stripped checked and put back together in a day. I have a inlbs torque wrench also if you need it?
All bits from here
http://www.5speeds.com

Thanks, but I'm more likely to replace rather than repair. The box had overheated by the time I got back home in forth, so I'm not expecting a simple repair.

I expect the parts cost would be much more than a used box even if the damage is minimal.

[ukkid35]

The Cerb obviously knew what the weather would be like and thought better of it.

[ukkid35]

Supateg said:

Very sorry to hear Paul.

I've just fitted the 5Speeds counter gear plate. I have Paul Cangialosi's book which helped.
stripped checked and put back together in a day. I have a inlbs torque wrench also if you need it?
All bits from here
http://www.5speeds.com

I'm looking to fit 5Speeds counter gear plate in the replacement box that I've bought, and I'm wondering where I can find an inlbs torque wrench. Thanks for the offer to borrow yours, but I'm on a horribly tight schedule and need to try to find one this weekend, any suggestions?

[ukkid35]

Thank you both that really helps.

I decided to pull apart the old box as practice. The point where I got stuck was removing the circlip that holds smaller of the two mangled gears (the one on the output shaft. Once that was out of the way the mangled gear would not shift, so I couldn't get the whole shaft out. As long as that doesn't happen with the replacement box I should be ok I guess.

It also took me an hour to find one of the parts that pinged away, but at least I've got a load of spares from the dead box if that happens with the replacement.

[ukkid35]

And this is what is confusing me

https://www.youtube.com/watch?v=E9csOWX_olE

At 9:05 he shows the outer race slipping off over the fifth gear, allowing the entire shaft to come out. However on my box the fifth gear is too large to allow that to happen, which means you can't pull out the entire shaft, without moving fifth gear off the splines.

If you can't get the shaft out then you can't set preload on the countershaft - checkmate.

[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.

[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.

[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.

[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.

[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?

[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.