Post
by timpaton » Sun Jan 15, 2012 4:31 pm
Gentlemen,
Firstly Thank you for all your assistance so far, i am genuinely touched at by helpful you all are, and am now well on the way to an MOT.
Secondly, and update.
After sleeping on yesterdays nightmare, i woke up and had a brainwave. I knew i had a long quite thick, about 3mm, piece of angle iron, when i say long i mean about four feet, in the garage.
Fortunately it had a long, approx 10mm diameter by 10cm slot already cut in it, so i drilled a 3/8 hole, approx 6cm away from the slot. I figured using this piece with the slot would allow me the flexibility to use both sizes of pulley / flange, with this tool.
I then stopped and labelled all of the flanges, i.e tbox 1 input, front, and rear, tbox2 ......
I then mounted this angle iron onto the first pulley of tbox 1, and drew around the semi circular piece of angle obstructing the main bolt from flange to box. Using a hand saw, i then cut away the semi circle to allow the 22mm socket to engage the main nut, and filed down the burrs.
I then wedged tbox1 against my vice on the far right hand side of my bench, and drew the angle iron arm up to about ten to nine, and clasped this onto the bench with a big g-clamp.
Using a 3 foot power bar, i then tried to release the main nut of the input to tbox1, but to no avail, so i heated the nut and the shaft /drive flange with a blow lamp for a minute or so. This worked a treat, and before i knew it, i had all three of tbox 1's and all three of tbox 2's drive flanges removed!
I simply then reversed the angle iron, and put the box at the other end of the bench, gripped it down with the g clamp (the angle, not the soft ally cased box) and used the power bar to reinstate the pulleys onto the alternate boxes.
I then reinstalled tbox2 with tbox 1's flanges into "Suzi" and bolted her up.
I drained the remaining oil, and put some fresh in.
I then repeated the leaving the tbox in neutral test, and running it through all the gears, and am happy to report that the clattering has gone!
However the speed (although stationery, so what i actually mean id the noise made by the output of the normal manual gearbox) related noise has not gone away, so now i guess i must change the gearbox. This is OK as i have a spare, so will do this next weekend.
P.S. i also found that i didn't need to take the exhaust off as the Haynes manual suggested.
Tim