Help needed - fitting r380 to v8

Right ho, we had a misunderstanding. I thought that the input shaft finished inside the bellhousing by 10mm, not out as you've shown it, but that's OK, and it doesn't affect your problem..

Taking the figures above, your input shaft is not causing the problem, there is a 9mm void left when the two flanges meet.

Trying the Ashcroft suggestion of grease will either work, or at least show you where the clutch is getting to on the splines because of the witness mark it will leave.

Failing that, have you any means of measuring the ID of the spigot bush and spigot accurately? Just wondering if it needs reaming?

id think spigots too long crank boss with spigot bush sits behind engine

Not relevant but don't see why you can't select gears with only the stub? Mine works just fine and its a knackered old box.

So I need to measure the outer face of the cover plate to the outer face of the friction plate.. Is that the thinking?

No, the dimensions you've given already show that the spigot length is OK.

It's the spigot (that's the input shaft, yes?) Is the right length overall, I was just worried about the splines bottoming out before the tip of the shaft bottoms out... As the splines will bottom out at the friction plate drive flange, and I don't have a measurement for that

I should add - that assumes that the spigot bush diameter is large enough all the way down to near the end.

Ah, see what you mean. Hadn't thought of that. Hang on a sec.

It's 35mm from the straight edge across the cover plate, to the buldge on the friction plate drive flange (so it's a bit further to the start of the splines)

A 13mm, deep, halfords socket is roughly the right size, and both bush and shaft check out by comparison

What is that 90mm measurement to? End of the splines?

No... ****... It's staring us in the face... 90mm vs 95mm

Oh bugger.. That's wrong too...

farmershort said:

It's the spigot (that's the input shaft, yes?) Is the right length overall, I was just worried about the splines bottoming out before the tip of the shaft bottoms out... As the splines will bottom out at the friction plate drive flange, and I don't have a measurement for that

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they can and a very common problem with td5s as people fit clutch plate the wrong way round and boss then jams against the shaft as the splines run out

jamesmartin said:

they can and a very common problem with td5s as people fit clutch plate the wrong way round and boss then jams against the shaft as the splines run out

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I've been assuming that John Eales is above such a mistake.

farmershort said:

I've been assuming that John Eales is above such a mistake.

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its not a td5 and splines run into the release bearing slide

Hold on.. Just done the maths..

There's 95mm of gap to take up, but actually we need to remove the 35mm from this, as from the shafts point of view, it's thin air... This measured across the face of the cover plate at the high points.

So 60mm of gap to take up, and 79mm of shaft... So it's not running out of shaft.

Front face for you James:

farmershort said:

There's no gear stick or assembly, just the very base of the shifter on the top of the gearbox... Ive tried selecting a gear with it and it doesn't work... Only goes so far... And I'm too scared of damaging it.

I have turned the flywheel from underneath with it bolted in the 5mm gap position, and the crane providing forward thrust, but it makes no odds... At a 5mm gap, the splines should be lined up OK.

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you wont hurt it just feel were it starts to go back or forward by rocking selector shaft then give it a sharp knock ie hammer shaft

as previously stated try with clutch off