GEARBOX

Jumping out of gear

• New selector balls and springs
• 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 your lever!
• Mole grips may get you out of trouble on 4 Spd broken stub!

 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?  

3 Spd 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 1^st and 2^nd at same time

• Weak synchro balls and springs – avoid being stationary in 2nd and then going into1st especially on a hill.  
• Replace 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 dipstick?

 
FLYWHEEL

 Coming loose

• Always 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 thrower
• Gently lap flywheel onto taper to ensure contact but check flywheel and/or crankshaft taper not already too worn

Removing when stuck

• Ensure good puller and use heat and penetrant

CLUTCH

Slipping

• Worn out?
• Oil on linings  
• Over filled gearbox
• Over oiled clutch thrust
• Worn gearbox oil seal

 Very vicious

• 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 DA7C Website

 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

PROP SHAFT
Vibration Problems
·                On Hardy Spicer prop ensure cross yokes are aligned front and back for
·                balance
·                Ensure carden pins blocks and housing are not badly worn. Renew as needed
·                good to keep blocks from moving towards shaft with packing washers or O rings
·                Bearing Fell out In Gibraltar !
·                Always ensure circlips are properly seated and have their flat side towards the
·                outside
·                Replacements sealed for life – do not pressure grease
·                If doing any diy reconditioning check that needle roller bearings are same size as
·                original
Noise From Propshaft
·             Fabric coupling flapping about – check/renew
·             Handbrake on early cars fouling fabric – check & adjust
·             Mini type gaitor come off housing or split

REAR AXLE
Crown Wheel and Pinion Stripped
·         Check/change oil frequently
·         Use white cable tie as dipstick
·         Use thin flexible tube when filling as crownwheel close to filler can cause false
·         level flow back
·         Do not overfill as oil can reach brake drums. Some use ½ pint instead of 2/3 but
·         check monthly* Use Morris EP140 or Castrol D140 Only Phil likes Molyslip in his gearbox and
·         axle!
·         Can use diff banjo bolt by torque tube as level plug
·         Do not block breather with paint on D axle
Keyway Stripped
·         Loose hubs
·         Check radius of key matches slot
·         Check hub nut goes to same place when tightened without key in order to make
·         sure that hub does not ride on key
·         Ensure half shaft end float exists after lapping hub onto shaft as gear can be pulled
·         against planet carrier with excess lapping
·         Do not slacken hub nut to get split pin in - some use shims, others face off nut,
·         some do not fit split pin, some use Loctite
·         Tighten hub nut really tight using long bar on socket and brake drum welded on
·         bar
Oily Brakes
·         Overfilled axle
·         Renew diff seals or modern lip seals - may need to rub down outer edge to fit in
·         tin retainers
·         Shaft Breaks
·         Old age/fatigue
·         Poor clutch control
·         Poor driver
·         Clutch problem
·         Kangarooing/clunk in reverse due loose torque tube anchorage
·         Get home on wheel nut /ball bearing between broken bits to lock diff.
Planet Carrier Breakage
·         Fatigue
·         Overlapped hub
·         Axle bent – check central location of half shafts plus check run out in lathe
Pinion End Float
·         Either shim or replace bearings on D axle and on banjo use locknuts on pinion
·         flange
Very Noisy
·         Use Ear Plugs !!
Early Torque Tubes Snap
·         Avoid using Chummy for big girl’s wedding !!

Phil Whitter