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Re: 1991 five speed repair Posted by Cmyles [Email] (#1126) [Profile/Gallery] (more from Cmyles) on Mon, 22 Jan 2024 11:32:33 In Reply to: Re: 1991 five speed repair, Merton, Mon, 22 Jan 2024 11:00:07 Members do not see ads below this line. - Help Keep This Site Online - Signup |
Merton,
If the pinion bearings were not properly pre-loaded that could effect the stack height in the described fashion. It will also result in rapid failure of the bearings and the entire gearbox. If the 24 mm nut is not screwed fully onto the shaft it will contact the back of the input assembly shaft and you won't be able to properly install that assembly or if you do get it installed there will be big problems right away.
Sometimes the synchromesh hubs or the gear bushings are reluctant to settle all the way into their intended location and that could cause what you're describing as well.
One clue as to whether the pinion bearings were properly pre-loaded would be how hard it is to rotate the mainshaft by hand. When new mainshaft bearings are properly pre-loaded the mainshaft will be quite hard to rotate by hand. If the pinion bearings have just been replaced and the shaft rotates easily then those bearings are not properly pre-loaded. You'll need an inch pound torque wrench with a 24 mm socket to determine the pre-load more accurately than just "hard vs. easy to turn" but that's a quick indicator.
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