Jumping out of gear
- New selector balls and
- 4 Spd box lever fouls cover
- Do not use packing washer on
top of gearbox to tighten things up
- Too much weight on
“specials” levers when bent back at right angle
- 3 Spd box has too much internal wear
Broken gear lever
- 3 Spd ball can drop off end
- 4 Spd breaks where gear
indicator plate circlip goes
- Carry the right 4Spd spare
lever as two lengths that engage in gearbox!
- Always check for wear on
- Mole grips may get you out of trouble on 4 Spd
3 Spd tops wear out
- Look for a better one!
- Repair with low temp. alloy “weld” rods or get built
up by specialist. Perhaps still made in NZ?
too much play in lever
- Worn selectors – braze up and remachine
4 Spd will not go into gear
- Clutch stuck on unused vehicle?
4 Spd synchro box locks in 1st and 2nd at
- Weak synchro balls and springs –
avoid being stationary in 2nd and then going into1st especially on a hill.
balls and springs
Oil leaks on carpet etc.
- Check 6 nuts and gasket on cover
- Check ring and its gasket is
screwed down on lever
- Too much oil in the gearbox – 4 Spd
one inch below filler hole thread. 3Spd
use engine dipstick as per handbook. Recommended
in handbook is 2/3 pint max. which indicates a bit more than 1 inch on
check not riding on key – make sure locking nut goes to same place without key
and then with key in place
- Check not pinching oil thrower
solid – need 40 thou between rear bearing and flywheel boss for rear main oil
- Gently lap flywheel onto taper to ensure contact but check
flywheel and/or crankshaft taper not already too worn
Removing when stuck
good puller and use heat and penetrant
- Worn out?
- Oil on linings
- Over oiled
- Worn gearbox oil seal
- State of linings
- Look at torque tube mounting
- Make sure clutch levers are all
same and fulcrum points and settings are within limits and all distances from
lever tips are same.
- See Roger’s article on levers on
Very little clutch travel
- Can be
lever adjustment and fulcrums worn
- See Sandy
Croall article on Cornish A7C website on clutch adjustment
- Be aware
of pinch bolt on clutch pedal combined with cross shaft pre positioning
- Watch out
for excessive length of taper pins on clutch thrust carrier