Transmission Parts 72+2 4 speed

[memini55]

Hello all,
Have disassembled the gearbox and found my issue with the poping out of third gear issue and now am looking to see if anyone has some used parts from a broken box. I will need a first gear which is the latter type with no bushing and an ID of 1.190" with 32 teeth. I am also looking for the hub of the 1st and 2nd syncro. I have located most of the other parts and am ready for reassembly.
Now for the cause the PO of the car had box appart and installed a non original circlip on the rear main shaft. This clip was not nearly as thick as the loading clip from original design and allowed the shaft to move and the spacer between the bearing and 1st gear broke in two pieces and then everything was able to float back and forth and caused the wear to the gear nose and hub tail. What a mess! The rest of the box is perfect so I would like to try to rebuild with parts if I can locate them.
You can call me at office at 800-728-1425 CT or my cell at 319-329-7110 or email at [email protected].
I had a post asking about a few issues with the motor and box and got no replies and am hoping someone might help this time arround.
Thanks in advance
Mark

[CBUEB1771]

Mark,
I have just finished going throught the similar gearbox on my +2S. This was a bit of a pain as the Lotus service parts lists were never updated to cover this late type gearbox. The snap ring you complain about is not shown in the parts books. In my case the ears on the snap ring retaining the rear bearing and 1/2 synchro hub had broken off and were lying in the bottom of the tail housing. Fortunately little other damage had been done. This snap ring is deceiving. Upon reassembly I found that the inner race of the rear bearing partially masks the width of the snap ring groove. This means you can't install a ring that fits the full width of the groove. Dave Bean carries a range of snap rings of different thicknesses to accommodate the stack-up of axial tolerances in the parts making up the assembly. I found I needed a snap ring 0.075" thick. This is much thinner than the receiving groove in the mainshaft which is about 0.130" wide. I wonder if Ford messed up on this design as the snap ring groove sure looks like it was intended to use the much thicker constant-section snap rings used to retain the 3/4 synchro hub and the speedo drive gear. I'll check my old parts collection for the first gear and 1/2 synchro hub. You should try Ray at RD Enterprises. I was impressed by the number of NOS parts he had for the gearbox

[memini55]

Russ
Thanks for your reply. I have been working with Ray and he has been great so far and he to is digging remains for parts.

So if I understood what you have said. I am aware of different thickness of clips to provide proper loading to the shaft and Ray has a few different ones available. My box was assembled with the snap ring with two eyelets and thin, about .070. If I understood your comments you have that same type of snap ring?

Maybe the big cause was the breakage of the spacer ring? When I did a rough assembly of the rear gears with the replacement spacer I still have about .125 of freeplay between bearing and spacer. Which was caused by the worn end of the gear and hub. Worst case Icould have the hub and the gear ends resurfaced and measure up for a shim washer and have one machined to fill the gap between hub and gear. Would like to replace parts if I can. Ray has a new hub assembly but no gear.

Thanks for looking thru your old stock plie.
Mark

[CBUEB1771]

Mark,
Yes, I had the same type of snap ring that you describe. It seems that axial motion of the rear bearing loaded the eyelets and snapped them off. In this case I was my own DPO and I didn't know those many years ago that you have to sort through a collection of them to find the optimal thickness. I still think that the designer at Ford intended to use the thicker, constant section type of ring and messed up on location of the groove or did not account for the stackup of tolerances on the synchro hub, oil slinger, bearing, etc, etc. When you say spacer, are you referring to the ring that holds the outer race of the rear bearing and gets sandwiched between the main case and tail housing?

[memini55]

Russ,
The spacer is in front of the bearing and runs againest 1st gear. It is a strange looking spacer as it has splines on the inside and a larger surface for the gear to run againest. It also has a large groove cut into a spot to allow oil to get down to the mainshaft and bearing.
I wish they would have updated the manual for this version of gearbox as it would help with a picture or two.
Mark
Let me know if you find any parts. Thanks

[garyeanderson]

Hi Mark

I have a few spare boxes, I may be able to help, not sure what you need. If you can't find what you need give me a call. My number is around... I think you have it already.

Gary

[CBUEB1771]

Mark,
I understand. What you call the spacer I call the oil slinger (yet another piece not shown in the service parts list). Dave Bean's catalog shows more information for the late type gearbox. If you don't have the Bean catalog I'll fax or scan the pages for you tomorrow. My scanner at home is broken. Gary does have quite a trove of hardware and information, just don't take any tennis balls from him as his yellow Lab will have already chewed them to death.

[CBUEB1771]

Mark,
Unfortunately I don't have any parts that will help. Many years ago I replaced the 1/2 synchro assembly and the second gear. Parts were readily available then and I threw out the worn parts. Good luck and let me know about the appropriate pages from Dave Bean's catalog. Of course I am obliged to mention that you should get your own from Bean if you don'y have one.