Content / Gearbox / Repair & Rebuilding - S3 E-Type

S3 E-Type

Repair & Rebuilding
counting needle rollers....

by Dave Lacey

Putting the Jag 4 speed back together

The parts I had purchased for the rebuild included: Synchro Rings, Pilot Bearing, Primary  Bearing, Tailshaft Bearings, Oil Seals, Needle rollers and (after inspection) the layshaft. I did some things wrong when rebuilding it. Most importantly I fitted the tailshaft bearing to the housing before fitting the housing to the box/shaft. Thats the wrong way round: fit the housing to the box (thereby checking fit of oilpump and fixing rear bearing in place) and then fit the tailshaft bearing.....

Firstly, i needed to re-fit the oilpump to the tailshaft housing, as you can see it's important to get the orientation of the pump components correct in relation to the housing:

gearbox_09-12-200568.JPG


One of the tailhaft bearings had been turning in the casting and was not a tight fit. Therefore I used a Loctite bearing retainer "glue" to hold it in-place:
gearbox_09-12-200532.JPG

here it is fitted (although, as i mentioned I had to take it out again later...):

gearbox_09-12-200533.JPG

Getting the needle roller bearing out of the input shaft proved a challenge, the casing is quite brittle and it had to be broken into little pieces to get it out:

gearbox_09-12-200534.JPG


New one went in fine after the oldcasing was levered out:

gearbox_09-12-200535.JPG


With the mainshaft stripped & cleaned on the bench, it's time to start adding the new needle rollers.
gearbox_09-12-200544.JPG

These are loose rollers and need to be packed in-place with grease:
gearbox_09-12-200546.JPG

Then the 3rd gear cluster can be dropped over the rollers (this is easier than it looks):
gearbox_09-12-200547.JPG

Then the selector (with new synchro rings) goes onto the shaft:
gearbox_09-12-200549.JPG

And now working from the other end of the mainshaft we add the lower gears, the 2nd gear rollers can start to be added:

gearbox_09-12-200552.JPG

And that gear dropped in place:
gearbox_09-12-200554.JPG

Same procedure for 1st & reverse and then the mainshaft assembly is ready.

gearbox_09-12-200556.JPG


To Prepare the casing & layshaft it's important to remember that the reverse gear selector must be fitted to the gear but not attached to the box yet.

gearbox_09-12-200563.JPG


The Layshaft gear has yet more needle rollers that must be packed with grease, here's a view with the thrust washer in place:

gearbox_09-12-200560.JPG

Then the (new) layshaft can be pushed partially into the box to secure the other thust washer:
gearbox_09-12-200561.JPG

And the layshaft gear added and shaft pushed though....at this stage it's easy...

gearbox_09-12-200562.JPG

Now fit the reverse gear selector, here I noticed that the reverse idler gear is chipped, dunno how that happened, but I assume it wont be a big problem.

gearbox_09-12-200564.JPG

With that completed the mainshaft can be manouvered into the box:

gearbox_09-12-200565.JPG


Finally, the primary shaft can be added
gearbox_09-12-200567.JPG
Submit comment
Subject
Username:
Comment: