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--- astra_conv:base_vehicle:restoration:gearbox_clutch [2013/12/03 16:46]
admin
+++ astra_conv:base_vehicle:restoration:gearbox_clutch [2014/04/22 20:46]
richard
@@ Line 1: / Line 1: @@
+====== gearbox ======
+{{indexmenu_n>020}}
+Already before pulling out the half-shafts, I drained the gearbox by removing the bottom cover. While the gear oil that ran out still looked ok, I found some disgusting "jelly" that had built up in the bottom cover.
+Gear oil, by the way, smells like the stale urine of a diabetic tomcat.
+{{astra_conv:base_vehicle:p1080075_gearbox.jpg?600|}} {{astra_conv:base_vehicle:p1080073_gearbox.jpg?600|}}
+After the engine and gearbox had been removed from the engine bay, they were separated. Left side: gearbox. Right side: Engine with flywheel, starter and clutch.
+{{astra_conv:base_vehicle:p1080300_gearbox.jpg?600|}} {{astra_conv:base_vehicle:p1080299_gearbox.jpg?600|}}
+New gaskets, including the seal rings for input shaft, half-shafts and gear selector shaft.
+{{astra_conv:base_vehicle:p1080326_gearbox.jpg?600|}}
+Side view of the gearbox with selector fork.
+{{astra_conv:base_vehicle:p1080314_gearbox.jpg?600|}}
+Joints and bearings of gear selector shaft, gear lever and all the moving parts in between are getting some attention.
+{{astra_conv:base_vehicle:p1080310_gearbox.jpg?600|}} {{astra_conv:base_vehicle:p1080308_gearbox.jpg?600|}}
+{{astra_conv:base_vehicle:p1080306_gearbox.jpg?600|}} {{astra_conv:base_vehicle:p1090413_gearbox.jpg?600|}}
+The top dome of the gearbox with gear selector shaft is being removed.  Note that the next three pictures were taken at a later time. On the next photo (left side), you already see the the motor joined with the gearbox. Right side: bottom view of the top dome.
+{{astra_conv:base_vehicle:p1090393_gearbox2.jpg?600|}} {{astra_conv:base_vehicle:p1090394_gearbox2.jpg?600|}}
+I learnt that for reassembly, the sliders and the "finger" of the gear selector shaft must be aligned correctly.
+{{astra_conv:base_vehicle:p1090397_gearbox2.jpg?600|}}
+Side cover cleaned, ready for painting.
+{{astra_conv:base_vehicle:p1080315_gearbox.jpg?600|}}
+Re-assembled gearbox. It is still drooling gear oil ...
+{{astra_conv:base_vehicle:p1080322_gearbox.jpg?600|}}
+For customization of the adapter plate, the gearbox is prepared for shipment to Marco and Rainer Lorey in Germany.
+{{astra_conv:base_vehicle:p1080325_gearbox.jpg?600|}}
+After taking the gearbox into operation again, it turned out that the radial clearance of the half-shaft bearings was too high. These bearings can be tightened by turning the toothed bearing ring, which is also visible on the two pictures above. A special tool is required to turn it. Since this tool was not available, I had to make my own one, out of an old bearing ring:
+{{astra_conv:base_vehicle:p1110845_gearbox.jpg?600|}}
+{{astra_conv:base_vehicle:p1110847_gearbox.jpg?600|}}
+A skilled mechanics guy (i.e. not me) used this tool to adjust the bearing clearance. He was quite successful. What however remained is a decent humming noise at very low speed, that occurs when accelerating. It depends on the speed of the wheels, not the motor, so it must come from differential gears, half-shafts or wheels bearings.
+{{actionlink>top|*** back to top of this page ***}}

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