Layshaft removal - little difficult?

Trying to strip the gearbox but having a few problems. I have removed the outer and inner gearbox covers no problem but nothing is coming out. The procedure says that I should take out the layshaft but it's not moving and nothing else will shift while it's in place. Can anybody give any tips for removing the lay shaft?

Many Thanks

Jamie

Badgerman said:

Trying to strip the gearbox but having a few problems. I have removed the outer and inner gearbox covers no problem but nothing is coming out. The procedure says that I should take out the layshaft but it's not moving and nothing else will shift while it's in place. Can anybody give any tips for removing the lay shaft?

Click to expand...

If it's still got the original drive side ball bearing, then the layshaft will probably be a tight fit inside it, and is most likely why it won't pull out?

If you heat the case, once it is hot enough the layshaft should then come out with the D/S bearing on its end, and that is probably the easiest way to remove the D/S bearing anyway. Once the layshaft is out, the old bearing can then be levered off the end of the shaft,

According to certain experts such as Mick Hemmings and the late John Hudson etc. it is not necessary for the layshaft to be a tight fit in the D/S bearing, so if it is found to be a particularly tight fit in the new (roller or Hemmings ball?) bearing inner race, then the end of the shaft should be eased down with emery tape.

Badgerman said:

I have removed the outer and inner gearbox covers no problem but nothing is coming out.

Click to expand...

With the selector fork rod removed, and the box in neutral, it should be possible to remove both 1st. and 2nd. gear pairs, also mainshaft 3rd. and both selector forks-even with the layshaft still in position?

Badgerman said:

Trying to strip the gearbox but having a few problems. I have removed the outer and inner gearbox covers no problem but nothing is coming out. The procedure says that I should take out the layshaft but it's not moving and nothing else will shift while it's in place. Can anybody give any tips for removing the lay shaft?

Many Thanks

Jamie

Click to expand...

Like LAB said, heat. It'll pop right out.

Use something like this. Aluminum heats pretty quickly. In my cold garage it only took a couple minutes.



Just heat the outside of the case around the bearing. The bearing will probably be stuck to the shaft but you can tap the gears with a rubber mallet or something non-destructive and the bearing will pop off.

I'll be putting the new bearing in my gearbox in the next couple days. Keep an eye on my gearbox rebuild thread.

Thanks for the help guys.....trip to the DIY shop for a blow torch and job done!!

Stay tuned for the next problem.......

James

Just thought I would ask. Have you removed the Selector Fork Spindle ? This must be removed (unscrewed) then all the gears and selector plates should just slide off. You will left with just the layshaft to remove. Then some heat will help to remove the layshaft with the bearing. I just completed the trans rebuild for my 75 850 MK3 that sat for over 30 years and things were difficult to dissamble but heat works wonders.

Yup, the torch gets a workout in gearbox rebuilds!