Gearbox/clutch drama

[mr hunt]

....and finally...For all the kiddies reading...my naked output shaft

 

[mr hunt]

just my two cents when my tranny was fixed this fall ( Roadster2013) a couple of gears apparently undamaged were replaced just for peace of mind .. I wonder if any would be useful to yours??

Cheers for the offer .. looks like I need both input and output 3rd/4th sprockets

 

[mr hunt]

Input shaft..first pic is slight damage to a dog on 5th gear.

second pic is the corresponding damage on the 4th gear dog

Third pic is 3rd/4th sprocket

You can see the damage to both sides of third where it picked up 3rd and 4th on the output at the same time ... good times!

 

[Nat67]

This whole thread has been thus far amazing, educational and inspirational . Especially @warp9.9 s long distance diagnosis and walk thru coupled with @mr hunt s can do attitude .
That shallow groove circlips placement is a major design flaw if ever I saw one and all it would take is a slightly off temper at manufacture of the circlips or over zealous factory technician over stretching the circlips during assembly to cause this right royal **** up ! Triumph should take responsibility for this , but as we all know full well they won't .
Is there a way to stop this problem ever reoccurring ?

 

[albertaduke]

Cheers for the offer .. looks like I need both input and output 3rd/4th sprockets

I will lookup my bill with the detail of parts changed if any match what you need I will send them to you

 

[Rocket Scientist]

This whole thread has been thus far amazing, educational and inspirational . Especially @warp9.9 s long distance diagnosis and walk thru coupled with @mr hunt s can do attitude .
That shallow groove circlips placement is a major design flaw if ever I saw one and all it would take is a slightly off temper at manufacture of the circlips or over zealous factory technician over stretching the circlips during assembly to cause this right royal **** up ! Triumph should take responsibility for this , but as we all know full well they won't .
Is there a way to stop this problem ever reoccurring ?

They do make a different style circlip that is made of very thin metal but wraps around two or three times (think of a couple wraps of a slinky). Not sure if they would be stronger.

 

[warp9.9]

4th gear bush

@warp9.9 is this the bush you were referring to in last night's post?

Yes those used to be just a bushing and then they had splined thrust washers (one on each side of the splined bushing) instead of the flange plus the old style bushing which was one complete splined bushing to cover both second and third gear bores.

Its hard to see but it looks like the cir-clip orientation was correct but hey its a pretty far view from here

Time to find a engine lathe so you can verify if the shaft is still straight and running concentric. I suppose one could just install the bearing on the shafts and shaft in the case. Then you could mount a dial indicator to check concentricity of the shaft but a lathe or a cylindrical grinder would be much faster. Say 5 minutes a shaft.

I cannot tell from the picture of the shaft assembled but did you bend the cir-clip removing it or was it Ob long prior to removal?

Oh and my wifey would strangle me if I laid the parts on her towel to take pictures

 

[jake shaw]

I'm pleased you found the cause. Good luck with the rebuild.

 

[mr hunt]

Yes those used to be just a bushing and then they had splined thrust washers (one on each side of the splined bushing) instead of the flange plus the old style bushing which was one complete splined bushing to cover both second and third gear bores.

Its hard to see but it looks like the cir-clip orientation was correct but hey its a pretty far view from here

Time to find a engine lathe so you can verify if the shaft is still straight and running concentric. I suppose one could just install the bearing on the shafts and shaft in the case. Then you could mount a dial indicator to check concentricity of the shaft but a lathe or a cylindrical grinder would be much faster. Say 5 minutes a shaft.

I cannot tell from the picture of the shaft assembled but did you bend the cir-clip removing it or was it Ob long prior to removal?

Oh and my wifey would strangle me if I laid the parts on her towel to take pictures

The towel is laid out on the kitchen bench - Mrs hunt is very understanding ...plus she doesn't really know where the kitchen is

The clip came off the shaft like that...I reckon the clunking I was experiencing was probably the clip sliding backwards and forward so it has probably been stretched on the shaft a while.

I'm surprised at how shallow the rebate is and can't see why an extra millimetre deeper isn't doable? Maybe a nominal 31mm clip would risk scoring the shaft over time. I plan to send some pics to triumph here in oz and ask for an explanation. I can't see how me hammering the gear shifter could cause this.There is so much attenuation in pressure through the various shifting mechanisms that even shifting with 10lb sledgehammer would translate all the way to the sprock and circlip.

2nd gear still has a splined thrust washer but it appears that is the only one ...anspd thanks for the heads up on measuring any distortion in the shaft, I hadn't considered that

 

[warp9.9]

The towel is laid out on the kitchen bench - Mrs hunt is very understanding ...plus she doesn't really know are the kitchen is

The clip came off the shaft like that...I reckon the clunking I was experiencing was probably the clip sliding backwards and forward so it has probably been stretched on the shaft a while.

I'm surprised at how shallow the rebate is and can't see why an extra millimetre deeper isn't doable? Maybe a nominal 31mm clip would risk scoring the shaft over time. I plan to send some pics to triumph here in oz and ask for an explanation. I can't see how me hammering the gear shifter could cause this.There is so much attenuation in pressure through the various shifting mechanisms that even shifting with 10lb sledgehammer would translate all the way to the sprock and circlip.

2nd gear still has a splined thrust washer but it appears that is the only one ...anspd thanks for the heads up on measuring any distortion in the shaft, I hadn't considered that

There is probably some wild calculation on cir-clip ID so as not to distort installing. That or the maybe the calculations refer to the Pitch circle of the splines. I never really thought about it just machined them to blue print specifications. Might have to do some research now as well as looking into the spiral snap rings and sizes
Dang time for another cup of coffee and a shower