Gearbox dissassembly question

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vuuduu21

vuuduu21

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In another thread i debated about replacing my layshaft bearing myself in my MK3. well after much encouregement from the members of this site, I ordered the parts Friday, and decided to get a jump on things this weekend.

I pulled the bodywork off to send out to Brent at the Vintage Vendor, and decided to takle the gearbox dissassembly. Things were going reasonably well until i got to this part. i got the 1st gear off the layshaft, and the first two gears off the mainshaft. reading L.A.B.'s proceedure on-line it seams like everything else should just slide out, but i cant for the life of me get the next laysahft gear and selector fork off. can anyone see if i am missing something?

Thanks, Rich
Gearbox dissassembly question

Gearbox dissassembly question

Gearbox dissassembly question
 
unscrew the shift fork slide shaft using the wrench flats on it.
 
Yep Concours knows and I add pay close attention to the way each cog faces as i've almost gotten mine back together right before discovering, after some fretting its does matter on a couple of em that can go on either way, ugh.
 
"unscrew the shift fork slide shaft using the wrench flats on it."

Yep, as per step 6 under D5 in the service manual, "Unscrew selector fork spindle and remove."

If you don't have the service manual, this is a good advertisement for why you should! :)
 
Thanks All. i have three manuals, factory, Clymer, and Hayes, i need to spend more time with my nose in them! got the gear clusters / forks out.

Do the last two gears stay on the layshaft?

Thanks,
Rich
 
The selector forks can be fitted either on main or layshaft but it is best to keep each fork with the gear it has been with. Take lots of close up photos as you take things out like those you see in more modern manuals. Another way to help is to thread gears onto a bar or length of wire in the order an correct way around as they were on shaft. As you clean gears you will see signs of which surfaces move or sat against each other and pay close attention to second gears they seem to wear more rapidly than the rest.
 
The selector forks can be fitted either on main or layshaft but it is best to keep each fork with the gear it has been with. Take lots of close up photos as you take things out like those you see in more modern manuals. Another way to help is to thread gears onto a bar or length of wire in the order an correct way around as they were on shaft. As you clean gears you will see signs of which surfaces move or sat against each other and pay close attention to second gears they seem to wear more rapidly than the rest.
 
I've been using your link LAB, great help. I laid the gears / forks in proper orientation by shaft in a metal tray.

Next up is the layshaft. I need to borrow a heat gun from my brother in law.

then gasket scaping till the new bearing and gaskets get here.
 
I'm just about at the same place as you vuuduu. Also using LAB's guide to help me through it. The layshaft came right out after heating the case for about ten minutes with a heat gun. So far so good!
 
"i have three manuals, factory, Clymer, and Hayes,"

Throw away those last two… ;)
 
Yeah I'm not a big fan of the Clymer or Hayes but the do have more photos than the factory manual.

The best source of info though is this site, and a few others like old Brits and LABs
 
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