Hey,

Made a start on my new box today.

Will be running a longer fifth than it has.

Removed the selector fork, and the bottom gear set (circlip one) no issues with a 3 legged puller (was surprisingly low resistance to remove)

Then wanted to remove the other gear (retained by bolt)

This one:

But the leg of my puller doesn't fit because of the casting, couldn't even get two legs opposite each other to fit, not sure if it's because of the gear size or not, but anyway, legs were too big but it's not my puller so I cant grind it down or owt,

Couldn't get it to twist to locate behind the gear.

So I ended up using a leg on its own and levering the back of the gear, rotating it each time so it was moving it square, this got it moving, but I wasn't keen on a single point load on the back of the gear (brittle) and also levering against the case wasn't favourable, I wasn't fussed if I damaged the gear as these will be binned, I didn't break it anyway but yeah.

Once it had moved about 6mm I could get the puller in to move it the rest of the way

Removed (note markings on casings from levering against it)

This method worked. And the slight marks on casing will be ok, and the gear isn't damaged.

However, I'm not keen on repeating this and risking damaging the gear I need,

Just wondering how others have done this?

Maybe thinner legs on puller or something?

Any suggestions welcome, just don't want to break the gear I want really!

Thanks

you shouldnt break the gear doing it that way as they are alot stronger than you think so i would just do it the same on the other gear and if you dont want to just make some thinner legs that attach to your puller thats what i do When i stripped my 020 box i made a whole pulley puller with 300mm long legs to get one of the gear stacks out as they had to come out as a whole assembly took me about 30 mins to make tbh but saved me having to spend over £100 buying a set of long legged ones or trying to find someone like a garage with some that would let me borrow them and now I've got them as a tool for life basically :)

Edited 28 June, 201214 yr by StinkyPete

Yeah I know I shouldn't really but they're very hard but brittle so can chip easily, I'd just be annoyed if I broke the good one, hence taking this one out first :)

Might use a heel bar to lever instead of the puller leg with a bit of tube haha

You've been more cautious than i ever have, i just used a bloody great big flathead screwdriver with a lot of care (same bit-at-a-time technique, too). I see the concern, if you're worried about chipping a corner then you could make a leverage tool using mild steel, or even brass strip might be strong enough. Just anything softer.

It's the other gear which is prone to breaking, as there's not much meat on the sync teeth and they're in a vulnerable position.

There is no harm in levering on the gear, they will stand that, what they don't like is hammer blows etc.

The secret of removing gears and bearings, is to keep turning them round and applying the pressure to all sides so that they don't 'lock' on the shaft as they are being removed,

Make sure that you remove any burrs from the case (preferably by careful scraping) otherwise you will have an oil leak.

Regards.

Done this btw!

No issues stripping the other box, they're not as tight as I thought also!

Circlip without circlip pliers was more difficult haha!

Thanks