TomF`s GSi Project Stage 2 - Trackday Version

[DavebGsi]

I remember when i got 6 new synchros fitted to mine, i gave it to a gearbox specialist because the garage i worked in had a press which could barely fit a wheel bearing

they had to stick the shaft in the freezer and then take it out and heat the gear! Had to do that to all 6 gears and they said they nearly picked up the phone to tell me it couldn't be done lol

 

[TomF]

I remember when i got 6 new synchros fitted to mine, i gave it to a gearbox specialist because the garage i worked in had a press which could barely fit a wheel bearing

they had to stick the shaft in the freezer and then take it out and heat the gear! Had to do that to all 6 gears and they said they nearly picked up the phone to tell me it couldn't be done lol

Ah dont be saying it cant be done Dave...!

I will get it fixed one way or another, otherwise car will be getting broke!

Heres a picture of an output shaft with no gears, so you can see what Im on about, the splines are just for the syncro hub, the 4 fixed gears are pressed / sweated on !

 

[Andy_Mk3]

Definitely think some heat and cooling will be required to shift any of that!

 

[TomF]

Ok more gearbox progress:

Output shaft gears pressed off cold using a 30 ton press, did the job just fine wasnt looking at the pressure gauge though haha



Brand new final drive bearing arrived from Gema Motorsport in Germany:



Stripped the donor 1st and 2nd gear assembly down and this it, we swapped my good syncros over :



And this is the shaft built up with my good syncros, ready to have the rest of the gears pressed back on, hopefully this week, on the home stretch now !

 

[TomF]

Final assembly pics, all built back up and ready to refit, just waiting on some Millers 75w110 oil now

 

[TomF]

All back together and ready for action, soon as this Covid-19 does one!

 

[DavebGsi]

nicely done mate! Bet your gutted,I was super lucky gettin that last track day in!

 

[Andy_Mk3]

Great job on the box there mate!

Did you find any specs on it for reassembly by any chance, stuff like pre-loads?

 

[TomF]

nicely done mate! Bet your gutted,I was super lucky gettin that last track day in!

Gutted aint the word, its all dressed up with no where to go, Sorn`d it before i took the box out, so bit pointless taxing it now with whats going on !

 

[TomF]

Great job on the box there mate!

Did you find any specs on it for reassembly by any chance, stuff like pre-loads?

Cheers , believe it or not the only pre load shims are for the diff bearings and the reverse gear set, haven`t touched either of those so just built it back up as it was!

 

[Andy_Mk3]

Cheers , believe it or not the only pre load shims are for the diff bearings and the reverse gear set, haven`t touched either of those so just built it back up as it was!

Ah fair one! When I put my diff in I couldn't find any preload specs for it, so just put the original shims back

 

[big e]

Cracking work on the box mate.