tomorrow i have to take an axle and axle tube etc off a gearbox and put them onto another one.
how hard is this? do i need special tools? can i do it by myself or do i need 2 people? anything else i need to know?
anything appriciated.
thanks
Nick
[ Edited on 28-8-2006 by Anthiron ]
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
As our gearbox has just started experiencing some problems, 11CAB kindly helped us out by tracking down a second hand gear box and pulling it apart for us (it turned out to be corroded to buggery inside, but that's another story). From what I could see, it is easier with two people, but is totally dooable with one. No special tools are required, but I would suggest you at least look at a service manual for the right procedure and torque settings for bolting it back up.
Ain't nothin' like the wind in your hair.
Should be straight forward.
Some big circlip pliers may be the only unusual tools needed unless the outer axle bearing is stuck on the axle.
I would do the assembly with the tranny mounted(perhaps on an engine stand?) so that the axle and tube is vertical,
and use an assembly manual for all the specifics.
Dont forget to get some new gaskets and a seal kit as a minimum.
Prob should put in a new outer bearing too.
westi wrote:That's mad Alan.
is it doable with the engine and box in the car?
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
OoooH, yes it is possible but the workspace is limited.
The proximity of the forks may requre you to remove some of the studs
that hold the axle tube retainer to the side cover...let us know.
westi wrote:That's mad Alan.
went down there.
got the retainer off the side, took the backing plate drum etc off. took the axle tube out from the spring plate.
then couldnt get the god damn bearing out!!!!!!
so i couldnt get the tube over the axle.
so i got a drum and a backing plate which i needed.
but still need an axle...i knew sometrhing would go wrong.
anyone have a short swing axle?
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
ok got me some new axles from karmen.
unbolted everything i needed to but you cant get the axle tube off without taking the box out of tyhe car
it doesnt clear the frame horns.
bugger.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
unless im missing some vital obvious thing? has anyone done this before with the box in the car?
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
Yes it can be done in the car,
I did it last weekend, but it is fiddly.
FAHRVERGNUGEN;
Description of a pleasurable sensation,
Experienced when a car and it's driver are in mutual harmony, A unique driving experience, Pleasure, Satisfaction,
A feeling experienced by Volkswagen Drivers.
do u have a procedure? anything inparticular i need to do?
ive been told to undo the 2 big bolts holding the banana mount to the frame horns and then jack up under the engine pivoting the engine and gearbox on the front mount slightly to get enough clearance for the axle tubes to get over the frame horns.
is this what u did? i havent tried this yet.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
yes undoing the 2 horn bolts would allow the box n motor to move up and probally clear the horn frame
be carefull when you finall put the axle into position that the fulcrum half plates dont jump out of position
It would have been easier to remove the motor n box and quicker
Later pans have a little more clearance in the fork area (for the IRS versions)
for CV clearance, but in your case if you loosen or remove all the tranny mounts,
You should be able to get the tube out.
A small hint when fitting the axle and fulcrum plates :
Pull the side gear out of the tranny, and fit the axle and fulcrum plates to that,
then put the whole assembly into the hole in the side cover.
Then put your circlip in to hold it in place.
westi wrote:That's mad Alan.
ok got it out:bounce
new axle is in. plate back in, circlip back in.
gotta go to work in a sec so tomorrow ill put the tube back on and do everything back up.
its looking good.
thanks for all the help its been greatly appriciated!!
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
Good on ya Nick. Get that beast rolling again.
not quite.
put the tube back on today and bolted up the spring plate and then was putting the bearing back on when i realised that the axel wont turn when it has and droop on the tube!!!! aaaarrrrggghhh!!!!
why? what have i done wrong.
also now that the new bearing is 3/4 on the axle and its F#c&ing tight. much tighter than the old axle i cant get it off with the vise grips and hammer.
even tried hammering it from hte axle tube side with the retainer plate undone to get it off that way.
a mate is bringing a puller around tonite.
gotta have it fixed by tomorrow nite or im screwed🙁
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
Provided that the gearbox is in neutral,
when you put the side gear and axle back into the diff,
you should be able to turn the axle with the gear in mesh.
Also, the circlip only retains the gear.
The axle can come out enough for the fulcrum plates to dislodge,
even with the circlip in.
The axle tube/bearing/retainer holds the axle in the correct position.
Keeping light inward pressure on the axle will keep the fulcrum plates in place
until the tube and bearing is fitted.
westi wrote:That's mad Alan.
ok got it done 😀
exactly what dangerous just said had happend. the axle had slipped foward letting the fulcrum plates creep to the back of the side gear holding the axle outwards and it was fouling.
got a mate over spent a few hours doing this and that, a trip to bunnings to find out that they only stock 2 kinds of circlip pliers which are both shite! having snapped 1 pair already we got a set of extra long needle nosers and took to them with the angle grinder. this did the job luckily.
anyway its back together. gotta glass my guard up early in the morning. then take mums car back, pump up my tire, bolt guard back on, re wire lights and hopefully it all works.
please everyone cross their fingers for me.
once again thanks for all the help here.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
the axle had slipped foward letting the fulcrum plates creep to the back
thats the biggest problem with swing axle gearboxes u would have been better off pulling the motor n box
i duno once we sussed what had happend it didnt take long to get it all back together. doing it again now id say id almost call it easy to do with the box in the car.
the most annoying thing was that circlip and bunnings not stocking anything but cheap crappy circlip pliers.
drove car again today after glassing the guard up and re wiring my lights.
damn it feels good to be in a decent old car again. not some new plastic thing with no bottom end and constant beeping reminders for keys, radio, headlights etc.
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
Told you it was easy...:party👍
tssnq.com.au
tha you did😏
62/60 model bug eye baja bug, (Full Build in Progress)
1974 Chevrolet Luv
1970 MK2 Ford Cortina GT
1979 Yamaha RX125 Two Stroke tracker project.
2004 Harley Davidson Sportster XL Custom
Good on you Nick, By the way you have e-mail. Baz
