Separating intermediate gearset

sportcoupe · 12-26-2014, 11:32 AM

Double check you put the intermediate gear assembly in the axle housing correctly. It is possible to install it 180 deg backwards in the rear axle housing.

If it is correct post picture of your issue.

Cayman Jan · 12-26-2014, 11:44 AM

Will do! Thanks so far!

cgtech · 12-26-2014, 01:52 PM

You will likely need to remove input shaft to install intermediate gear. Dont fret, this is no big problem.

Cayman Jan · 12-27-2014, 11:58 AM

So I have removed all the gear shafts. Will need to polish down the diameter of the intermediate shafts a bit, as it was hellish to remove the ball bearings. As this is the shaft (with one gear)that was in the kit, I guess this is quite normal.
Will do another attempt today.
I did find a very useful (old) thread on this eminent forum, called D&D PDS High Speed Motor and 8:1 High Speed Gear Experiment, with very useful pictures!

( I find it incredible that there is no Installation Manual enclosed when you buy those expensive gearsets!)

cgtech · 12-27-2014, 01:04 PM

I guess the "take notes, take pictures during disassembly" method rings true again.

Cayman Jan · 12-27-2014, 01:43 PM

Quote:

Originally Posted by cgtech

I guess the "take notes, take pictures during disassembly" method rings true again.

No need for a such simple construction. What gave me problems is how the new gears fit inside the housing!

Instructions from the gear manufacturer should have been enclosed!

sportcoupe · 12-27-2014, 05:09 PM

Having done several gear swaps there was never any need for instructions. The gears fit together nicely if assembled correctly assuming the correct parts were ordered and/or shipped as a matching set.

Men don't read instructions anyhow.

Cayman Jan · 12-27-2014, 08:02 PM

So true!!
I did the front end with the disc brakes today. Adjustment of that over the next couple of evenings.

I am thinking of refurbishing and painting the outside of the diff and axle tubes before I attempt the inside assembly.

Cayman Jan · 12-31-2014, 07:36 PM

Done! It seems the new gear was not pressed on properly. The nice guy that helped me also drilled a new hole for that securing pin.

sportcoupe · 12-31-2014, 08:45 PM

Very good. Thanks for the update.

12-26-2014, 11:32 AM	#11
sportcoupe Gone Wild Join Date: Sep 2012 Location: Savannah, GA Posts: 2,760	Re: Separating intermediate gearset Double check you put the intermediate gear assembly in the axle housing correctly. It is possible to install it 180 deg backwards in the rear axle housing. If it is correct post picture of your issue.

12-26-2014, 11:44 AM	#12
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16	Re: Separating intermediate gearset Will do! Thanks so far!
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16

12-26-2014, 01:52 PM	#13
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: Separating intermediate gearset You will likely need to remove input shaft to install intermediate gear. Dont fret, this is no big problem.

12-27-2014, 11:58 AM	#14
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16	Re: Separating intermediate gearset So I have removed all the gear shafts. Will need to polish down the diameter of the intermediate shafts a bit, as it was hellish to remove the ball bearings. As this is the shaft (with one gear)that was in the kit, I guess this is quite normal. Will do another attempt today. I did find a very useful (old) thread on this eminent forum, called D&D PDS High Speed Motor and 8:1 High Speed Gear Experiment, with very useful pictures! ( I find it incredible that there is no Installation Manual enclosed when you buy those expensive gearsets!)
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16

12-27-2014, 01:04 PM	#15
cgtech Over This Interview Is... Join Date: Jun 2012 Location: AZ Posts: 17,449	Re: Separating intermediate gearset I guess the "take notes, take pictures during disassembly" method rings true again.

Today
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12-27-2014, 05:09 PM	#17
sportcoupe Gone Wild Join Date: Sep 2012 Location: Savannah, GA Posts: 2,760	Re: Separating intermediate gearset Having done several gear swaps there was never any need for instructions. The gears fit together nicely if assembled correctly assuming the correct parts were ordered and/or shipped as a matching set. Men don't read instructions anyhow.

12-27-2014, 08:02 PM	#18
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16	Re: Separating intermediate gearset So true!! I did the front end with the disc brakes today. Adjustment of that over the next couple of evenings. I am thinking of refurbishing and painting the outside of the diff and axle tubes before I attempt the inside assembly.
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16

12-31-2014, 07:36 PM	#19
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16	Re: Separating intermediate gearset Done! It seems the new gear was not pressed on properly. The nice guy that helped me also drilled a new hole for that securing pin.
Cayman Jan Not Yet Wild Join Date: Nov 2014 Posts: 16

12-31-2014, 08:45 PM	#20
sportcoupe Gone Wild Join Date: Sep 2012 Location: Savannah, GA Posts: 2,760	Re: Separating intermediate gearset Very good. Thanks for the update.

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