DHdev WIP thread (56k No!, lol)

Right....Got to work on the box after work today. Started around 12.30pm was flying along, had it all apart and cleaned up the casing a bit

http://i41.photobucket.com/albums/e2...v/DSC00736.jpg

http://i41.photobucket.com/albums/e2...DSC00737-1.jpg

http://i41.photobucket.com/albums/e2...DSC00738-1.jpg

Swapped the pinion over to the new cluster

Old, standard F13 cluster

http://i41.photobucket.com/albums/e2...v/DSC00740.jpg

New HH SCCR cluster

http://i41.photobucket.com/albums/e2...v/DSC00739.jpg

Weighed them SCCR 13.45kgs

http://i41.photobucket.com/albums/e2...v/DSC00741.jpg

Standard 13.3kgs!!!! DAMN! I've gained 150g

http://i41.photobucket.com/albums/e2...v/DSC00743.jpg

All the above was done in no time, I then spent ages trying to get the cluster in, but it kept stopping about 10mm shy of the casing. So I tried Lee303, but he was baffled too! So i thought I must be being a pansy and decided to gentle tighten the bolts to close the gap. Once it was back together I checked the input shaft to see if everything was spinning as it should and to my surprise it wasn't. So back apart with it all to inspect what was up....

http://i41.photobucket.com/albums/e2...v/DSC00745.jpg

http://i41.photobucket.com/albums/e2...v/DSC00746.jpg

It seems the gear set is fouling the casing, probably due to loose tolerances on the casting. So I called it quits for today and will go in early monday morning and pull the diff out and machine down the casting. Also gives me time to buy gaskets and a new release bearing.

hmm, thats very odd, but it does seem to be a casting issue, pretty sure mine cleared there but fouled in another place, oh well at least its obvious enough
oh, and told you it would be heavier, better steel is more denselol

Nice mod that OLi.

Pah, whats 150 grams?

Quote:

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Originally Posted by craig green

Nice mod that OLi.

Pah, whats 150 grams?

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Too much, thats what!!!

Don't worry, I'll find a way to lose 150g from somewhere :D

Shave your nads.

Already done :( Maybe I could lose a few teeth :D

Quote:

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Originally Posted by craig green

Shave your nads.

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lol

Oli, this was the issue that caused me a similar problem.

What you will possibly find is that the SCCR gear near the top (the end which runs in the bearing in the casing) of the main shaft is a little bigger diameter than its helical counterpart as catches on the casing. I had to grind a little of this away (unfortunately you have to remove diff etc due to ally filings) and hey presto all was good.

It took me a bit of head scratching as its not totally obvious where its fouling the casting :tard:

HTH

Quote:

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Originally Posted by tom_beverley

lol

Oli, this was the issue that caused me a similar problem.

What you will possibly find is that the SCCR gear near the top (the end which runs in the bearing in the casing) of the main shaft is a little bigger diameter than its helical counterpart as catches on the casing. I had to grind a little of this away (unfortunately you have to remove diff etc due to ally filings) and hey presto all was good.

It took me a bit of head scratching as its not totally obvious where its fouling the casting :tard:

HTH

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Thats exactly the problem i'm having :) You can see the marks from the teeth in the last two pics :thumb:

Ah yes you can clearly see there, I couldn't see the pic yesterday (work computers block 99% of pics :mad:).

Mine was really difficult to spot as it didn't leave any marks on the casing, bloody tolerances lol

Collected my gaskets, release bearing (rip-off from Vaux) and Oil, yesterday evening.
Came into work an hour early this morning. Cleaned up the casing (removed the swarf from the grinding that was required to fit the gearkit) Gears are back in, diff is installed and bearings preloaded. Just need to fit the selector turret, release bearing and diff cover. Pics later :thumb: