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D5 Gearbox Problem
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Topquark
Worcester
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July 8, 2020 - 5:18 pm
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Attempting (heavy emphasis here) to rebuild a D5 and having an issues with gearbox. On assembly of gear cluster all works ok with selections and neutral but when left hand casing tightened up neutral disappears. It is still there until the last bit of tightening and on further investigation it seems that the 32T layshaft pinion is the cause as I can simulate the problem by apply a small amount of pressure on the pinion when the cases are still split. I’ve checked that there’s nothing missing from the cluster. I’ve replaced all bearings and bushes and there doesn’t seem to be any tightness but on reading other posts am now concerned about the bush alignment.
Any thoughts from people who have a lot more knowledge than this beginner would be appreciated 

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cocorico
Central France
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July 8, 2020 - 5:51 pm
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Do you have the rear casing location dowel fitted? If not the cases can be misaligned enough to jam when tightened.

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sunny
Norfolk
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July 9, 2020 - 10:04 am
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the  only  thing  i  have   is  moor for   uthers    me  being  absolotly   «censored»   at   speling  i  memarise  most  stuff coz  it sounds  funny   but  just  have tryble     reading    wot  iv  rote down    its like  this   my  note  book  gone   walkabout     it was   full of  sizes  &  drewing  of like  how  deep a bush  &  bearings    in  situe    &  if  its  a crackshaft   il say    or  gears   do a  dummy  asembly  run  with  said  bits  so in this  situ  put  all gear parts  in the cases  NO c/shaft  or  hermatyt     &  see  if  it  works           sort any  probs   time & time  again ,.  so  that s how  i do it  chaps     id like  to say  thank  you  to all  you  guys   that  can   understand  my  input    grate  stuff  thanks     Sunny

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DaveP.
Tutbury, Burton upon Trent.
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July 9, 2020 - 10:53 am
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Keep it up Sunny, I for one appreciate and admire your knowledge.

Take Care,

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Blue Heeler
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July 9, 2020 - 2:04 pm
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Spot-on Sunny, couldn`t agree more. 

Can also use couple of tight-fitting bolt shanks in place of crankcase hollow dowels, while engine`s on the bench. 

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Topquark
Worcester
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November 25, 2020 - 8:08 pm
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Hi again. Something of a hiatus in my attempts borne out of frustration but also other events. However thanks to the advice from Sunny I started again and by a process of eliminating the pinions one by one determined it was actually the right side mainshaft bearing wasn’t seated far enough in so there just wasn’t the right space available. That’s sorted now and have now done a “dry” assembly of engine which has revealed the need for several replacement or indeed missing parts.

Thanks again for the advice; will probably be back for more before too long 😀

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Stoo63
GLASGOW
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November 25, 2020 - 8:53 pm
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Hi Eamon. Glad to hear that your making some progress. To the put your mind at ease and while you've got the cases apart, it might be worth sourcing a set of earlier gearbox shafts which are generally considered to be more reliable. There's loads of threads on the topic. Have a look  ** Please log in to view ** for previous discussion. 

Stewart

 '55 D3 Battery; '58 Square Four (project); '59 D1 direct lighting plunger; '59 Tiger Cub; '60 5TA;  '76 FS1-E; '91 GTR 1000;  '97 Honda Sky SGX50.

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