Gazzar Posted November 5, 2023 Share Posted November 5, 2023 I've a 101 project. The standard gearing is quite low, so I'm fitting an over drive. Not because it's a cool name for a device, nor because I like having loads of levers in the cab. Purely for economy and having the option for a decent road speed. The 101 gearbox is from the same design as used in the original range rover, a rugged 4 speed manual box designed for the V8. The box was designed for use in both vehicles to spread the development costs. There are new overdrives for this box, but they are quite expensive, so I went with a second hand Fairey, which, to ensure it came complete, was still fitted to a gearbox. Parts availability isn't great, with the clutch sleeve that connects the over drive to the main box being unobtainable. I have a second scrap overdrive for parts, so aim to make one good from two. Bearings are available and I've bought I kit from Gavin, who has a good supply of parts. Note the modified selector shaft pin hole. 2 Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 GLF classics. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 I'm following Gavin's instructions, mostly. Take off the top plate to reveal the selector fork. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 That's an allen key retainer in there. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Gentle cleaning of the thread and user of penetrating oil and the screw came out. Some imperial fitting, this just stops the shaft from coming out of the casing. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 The bolt for the selector fork is 1/2 socket. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Removing the selector shaft wasn't difficult, I twisted it and pulled at the same time. Once the fork was loose, I stopped pulling out the shaft, and carefully pivoted the fork and pads around the synchro hub until I could lift it out easily. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Then pull the shaft all the way out. A ball bearing came out, so I undid the hex socket screw underneath, pulling out a spring and a plunger. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Then remove the back plate, according to the instructions. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Revealing big gear stuff. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 I cleaned around the layshaft then used a drift to gently rotate the shaft prior to pulling the shaft out with a strong magnet. It was slow at first, but no real drama. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Out. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Removing the smaller of the two circlips allows the mainshaft to come out from the front. Carefully, as there are a lot of bearings and thrust washers at the back, note the taper on the washers. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Four things. Taper away from the needle bearing. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 The mainshaft, and the scrap one. And the bearing that was in front of it. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Then I did this different to Gavin's instructions. I took out the synchro baulk rings and associated washers. One comes out the front. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Then I moved the hub aside and removed the other baulk ring through the inspection hole. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 And, careful not to move the inner, the hub out the same way Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Note the orientation. Quote Link to comment Share on other sites More sharing options...
Snagger Posted November 5, 2023 Share Posted November 5, 2023 It looks very similar in construction to the monstrously bad unit you handled for me a couple of years ago. They are a fun little project. I hope you don’t find parts that have welded themselves together and need a great deal of brutality to strip like mine did! Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 And lots of washers. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 Then, as I'd fully removed the hub and man shaft, I used a hammer handle to drift out the rear bearing. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 The lay gear is sandwiched between more needle bearing sets and a shim. This is the rear set. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 And this the front. Quote Link to comment Share on other sites More sharing options...
Gazzar Posted November 5, 2023 Author Share Posted November 5, 2023 The lay gear just comes out. I stuck the lot together for tidiness. Quote Link to comment Share on other sites More sharing options...
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