Then the rest of the good gear could go in:
When putting the input shaft in, you have to make sure you've got the synchro hub setup on the upper shaft (input gearsets) with the three little tabs inside the hub held in place properly by two circlip like springs. Once you've got these in you have to install the synchro ring.
Here you can see the gold synchro ring and one of the little tabs in the hub (difficult to see in this pic as you can only see the end of it):
In this pic you should be able to make out the little tab better, the bottom edge of the selector fork is in line with the end of the tab:
It's very important that these little tabs are lined up with their slot in the gold synchro ring, otherwise it either won't work or one or more of the tabs could fall out:
This is a mock up of the gearbox together after I snapped the soldering on one of the low range oil feeders - I'm glad I did this as I learnt a few things about putting it together and I also realised over night that I forgot to fit the little arm piece on the selector arm that keeps the arm in the selector fork pieces (if that makes sense) to select gears. Anyway, gearbox:
Once I actually got the box back together properly with silicone and bolts etc it was time to put it back under Ruby Scoo. I did this with some jack stands and the aid of a motorcycle jack:
This took a bit of effort to get it in the right spot and on the right angle on the jack, but once it worked all went well. I also found that I had two dowels on one side - one in the engine and one in the gearbox... So I fixed that. I also made sure I had the clutch fork and throw out bearing fitted!
Gearbox going in on the motorcycle jack:
All went relatively well after this. I've still got a couple of things to do but she runs and did a ~160km "shake down" run today. And making friends already:
A couple of things about the new box:
- the ratios seem closer together than the last box (I believe it ran the RX turbo ratios)
- speedo reading is about 4km/h UNDER your actual speed, going to see if I can mess around with the cluster to make it more accurate or show a little bit over actual speed
- the 5th ratio I've chosen rev's higher than I calculated, will see what happens there, I *might* swap it back, but it's a lot of work!
- I forgot to add a stud for the lower starter motor mounting bolt, so I've just got one bolt holding it in - I'm not fussed on this as I've run like this before without issue
I forgot how tall Ruby Scoo is! It's awesome to be back in her but she seems to lack that bark I remember her to have. Will have to check out the induction noise through the snorkel as I haven't checked that out yet - too cold to run with the window down!
I've also lost that annoying vibration I had at about the 3000rpm mark - I think it was due to one of those little tabs in the synchro hub falling out in the old box (found it after an oil change!).
Overall I'm pretty happy with it. Ruby Scoo rolled over to 492,000km on the shake down too.
Now to hook up the low range lever and hit some tracks!! When will be the question...
Cheers
Bennie