concours
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- Joined
- Dec 29, 2011
- Messages
- 8,731
I had the opportunity to repair my failed transmission (still working, but 2nd had a funny "thump, thump, thump" noise.
Disassembly revealed a LOT of damage....
I set to work inspecting (the case, sleeve gear and first gear lay were the only usable moving parts) and ordering parts. When I began assembly, the first stoppage was the second gear main would not slide all the way onto the splines on the new mainshaft :x Note the spline cut DEEP in one index only. I tested the OLD gear, would not go on. Tried the NEW gear on the OLD shaft, fit right on, so it confirms the NEW shaft was not acceptable.
3 hours of stoning by hand with a 1/4" triangular stone got the gear to go on, if only in ONE orientation. I match marked it with paint marker for assembly. Had I not been leaving on a trip, I would have sent the shaft STRAIT BACK to AN. Machine shop dumpster material.
The horrid spline surface finish is visible here:
I was finally able to get it assembled. The obligatory rollover by hand revealed a once per mainshaft revolution bind. I re-checked everything, used bluing to look for unusual contact patterns on gears, shift forks, etc. Nothing found. I kept removing gears, forks, etc., until only shafts left. bind was present with 4th set, but gone without. sufficient backlash present. I set up an indicator on the mainshaft at the clutch end, good, set up on the sleeve gear out board of the sprocket, .010" runout... WTF... "BENT" sleave gear? must have a crumb between the gear/bearing (NOT my usual MO!) so, apart it comes... then I remember saying earlier... "boy, that radius on the inner race looks unusually small. Oh well, it must be good, U.K. made bearing, sold by AN at three times what a common commercial bearing goes for, it MUST be ok"
WRONG. After more inspection, bluing, measuring, it's shown the radius hits before the precision ground shoulder on the sleeve gear contacts the bearings race as designed. This provided an inaccurate locating of the sleeve gear, causing it to orbit, and runout as observed. Meanwhile, there is significant time invested (WASTED!! :x ) here, the heating of the case, outer seal glued in, etc.
Here, you can see the daylight between the inner race and sleeve gear, a .005" feeler gage confirms it :shock:
Genuine AN quality, and ALL the money paid for these horribly low quality parts. :roll:
The AN bearing shown with a radius gage fouling :shock: :x
And the $25 commercial grade bearing from my local bearing supplier with an industry standard radius
So, after laying out two tall for a hand full of parts, my time wasted reworking, backtracking and improvising is huge. The quality is dismal. Whoever (NOT a machinist) made that mainshaft, inspected and packaged it, should have it jammed up their nostril so they never lose sight of their work. :x :mrgreen:
Disassembly revealed a LOT of damage....
I set to work inspecting (the case, sleeve gear and first gear lay were the only usable moving parts) and ordering parts. When I began assembly, the first stoppage was the second gear main would not slide all the way onto the splines on the new mainshaft :x Note the spline cut DEEP in one index only. I tested the OLD gear, would not go on. Tried the NEW gear on the OLD shaft, fit right on, so it confirms the NEW shaft was not acceptable.
3 hours of stoning by hand with a 1/4" triangular stone got the gear to go on, if only in ONE orientation. I match marked it with paint marker for assembly. Had I not been leaving on a trip, I would have sent the shaft STRAIT BACK to AN. Machine shop dumpster material.
The horrid spline surface finish is visible here:
I was finally able to get it assembled. The obligatory rollover by hand revealed a once per mainshaft revolution bind. I re-checked everything, used bluing to look for unusual contact patterns on gears, shift forks, etc. Nothing found. I kept removing gears, forks, etc., until only shafts left. bind was present with 4th set, but gone without. sufficient backlash present. I set up an indicator on the mainshaft at the clutch end, good, set up on the sleeve gear out board of the sprocket, .010" runout... WTF... "BENT" sleave gear? must have a crumb between the gear/bearing (NOT my usual MO!) so, apart it comes... then I remember saying earlier... "boy, that radius on the inner race looks unusually small. Oh well, it must be good, U.K. made bearing, sold by AN at three times what a common commercial bearing goes for, it MUST be ok"
WRONG. After more inspection, bluing, measuring, it's shown the radius hits before the precision ground shoulder on the sleeve gear contacts the bearings race as designed. This provided an inaccurate locating of the sleeve gear, causing it to orbit, and runout as observed. Meanwhile, there is significant time invested (WASTED!! :x ) here, the heating of the case, outer seal glued in, etc.
Here, you can see the daylight between the inner race and sleeve gear, a .005" feeler gage confirms it :shock:
Genuine AN quality, and ALL the money paid for these horribly low quality parts. :roll:
The AN bearing shown with a radius gage fouling :shock: :x
And the $25 commercial grade bearing from my local bearing supplier with an industry standard radius
So, after laying out two tall for a hand full of parts, my time wasted reworking, backtracking and improvising is huge. The quality is dismal. Whoever (NOT a machinist) made that mainshaft, inspected and packaged it, should have it jammed up their nostril so they never lose sight of their work. :x :mrgreen: