lt77 rebuild

So then it's that time again, Yes more questions and advice
I think I've decided to give the lt77 rebuild (main shaft change due to wear on the output splines) a bash.
To be honest I'm still not sure if I'm biting off more than I can chew. But I had my last box in bits slightly to change the 5th gear baulk ring and didn't seem too bad. (I know that's nothing compared to this but we'll see how it goes)
I have no real need to do this other than out of interest and seeing how stuff works Plus to take my mind off my other project that I've got ****ed off with.

Anyway, What I have is a 50A suffix G box.
Output splines are worn so needs a main shaft, I've have had a look about and have come up with part number FTC1446.
I think it's right but can anyone confirm?
Where to get it from. I see ashcroft sell them, But unsure of brand supplied.
Or do I order from somewhere I can choose the brand. I.e britpart/bearmach/allmakes/lr etc?
On that subject which is best as I assume genuine lr will be silly money.

I was going to say is it worth buying a full rebuild kit also, But I assume the best way is to strip it and measure tolerances and order what's needed.
Or is their certain things I need for the main shaft replacement?

Anyway I'll leave it at that for now as I've rambled on long enough for now and I'm sure there will be many more questions to come.
I'll just finish with this picture to show the scruffy thing I'm starting with.
If all goes to plan I should enjoy this little project and challenge and as always advice and thoughts needed

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To be honest I'm still not sure if I'm biting off more than I can chew.

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Now no-one on here will think that!

Sounds like a great project. Lots of learning to be had there. Is the plan to sell it? If not, are you not worried about recouping your costs?

Al2O3 said:

Now no-one on here will think that!

Sounds like a great project. Lots of learning to be had there. Is the plan to sell it? If not, are you not worried about recouping your costs?

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Probably keep it, I'll no doubt have another project at some point and I'll stick it in that. I don't know really, It's just a little something to put my mind on and keep me busy/happy as I'm a depressed c*nt at the moment. But it depends how money is and if I get some work.

As for recouping costs, The gearbox doesn't really owe me anything so it's only the parts and my time, Which I've got loads of at the mo. So not overly concerned
Although when I price bits up it could change
Looking forward to it actually

ftc1446 is the right shaft for suffix g , suffix g is the strongest and best lt77 imo,britpart shafts have been better than bearmach ones,strip it and see but its common to replace the main bearings (ukc8lg,ftc317g, ftc248g rtc6751g,rtc2914g)and reuse needle roller bearings unless damaged and new baulk rings(frc8232 x 5) synchro springs (ukc31l x 6)gasket and seal kit is (rtc6797)

Why depressed? Are you working at the moment? Your very talented, mate. Just focus on that

jamesmartin said:

ftc1446 is the right shaft for suffix g , suffix g is the strongest and best lt77 imo,britpart shafts have been better than bearmach ones,strip it and see but its common to replace the main bearings (ukc8lg,ftc317g, ftc248g rtc6751g,rtc2914g)and reuse needle roller bearings unless damaged and new baulk rings(frc8232 x 5) synchro springs (ukc31l x 6)gasket and seal kit is (rtc6797)

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He's a legend, isn't he.

jamesmartin said:

ftc1446 is the right shaft for suffix g , suffix g is the strongest and best lt77 imo,britpart shafts have been better than bearmach ones,strip it and see but its common to replace the main bearings (ukc8lg,ftc317g, ftc248g rtc6751g,rtc2914g)and reuse needle roller bearings unless damaged and new baulk rings(frc8232 x 5) synchro springs (ukc31l x 6)gasket and seal kit is (rtc6797)

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Cheers James, I'll go with the britpart shaft then.
I'd rather do a proper job so just had a quick look at prices of the other stuff you've listed.
Nothing too expensive so will probably replace all.

Al2O3 said:

Why depressed? Are you working at the moment? Your very talented, mate. Just focus on that

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Nope, No work at the mo Maybe depressed is the wrong word, So very unhappy, But it's hard when people ask what's wrong when the truth is you don't know yourself.
Just don't know why I bother doing anything. But then to be honest I'm my own worst enemy and get myself down over nothing.
But that's why I'm doing stuff like this as at least I'm happy and content while I'm doing it

Al2O3 said:

He's a legend, isn't he.

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Yep, Helps out no end

aaronmorris said:

Just don't know why I bother doing anything.

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Because being busy is what makes us happy.

Al2O3 said:

Because being busy is what makes us happy.

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Too true, I hate having nothing to do.

Ordered the bit's last night, Main shaft said 3-4 days so hopefully here before the weekend. But at least it'll give me chance to paint the casing and get everything cleaned up.

Anyway I made a start with it today. (seen as I couldn't finish the lt230 ) All went pretty well and much less daunting than the last time I had one in bits the change the 5th gear baulk ring.

Removed the extension casing with it on the floor, But then though why not stick it on the bench :doh:

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Removed bell housing, Stuck it in vice and removed casing.
(Yep theirs loads of pics missing as I forgot )

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Lifted pinion shaft off.

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And the lay shaft.

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Removed main shaft assembly and left with a bare(ish) casing.

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Everything appeared to be very clean. Much to my surprise.

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Removed one bearing on the main shaft with a puller.

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The other one, The pullers I had where either to big to get in for not long enough. So I um'ed and ah'ed for ages as to how to get it off.
In the end I stuck it in the press and it came off with ease

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Removed the rest of the gear/syncro assemblies and left with a bare main shaft. (The bit I'm replacing)

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And that was that. The rest of the bearings look like they're going to be interesting to remove to say the least. No idea how I will as of yet. But non of my pullers will fit.

Also need to get this bearing race out of the pinion shaft, I assume I'll need an internal puller of some kind.
But I think I'll try and make something for that.

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for inner pinion i have a slide hammer and expanding mandrel, though you could run a bead of weld round the race and it will shrink it, if you use coated baulk rings they must have a clearance of 15 thou uncoated 25 thou, bearing races are best loctited in bearing plate and case once shimmings correct

Good way to get bearing tracks out is to lay a bead of weld on the track itself as it cools its shrinks, obviously if you want to use the bearing again its a no go!

Must type faster!

jamesmartin said:

for inner pinion i have a slide hammer and expanding mandrel, though you could run a bead of weld round the race and it will shrink it, if you use coated baulk rings they must have a clearance of 15 thou uncoated 25 thou, bearing races are best loctited in bearing plate and case once shimmings correct

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Yes I have seen the expanding mandrel type things. But don't really want to buy a set at this moment in time. As much as I'd like too.
I have a slide hammer so hopefully I can make something that'll work. Or as you say it's a case of running a bead of weld around

On the subject of baulk rings. I remember last time you mentioned 15 thou coated 25 thou uncoated.
But in real terms what is the difference? i.e does one last longer that the other or do the job better.

On the shimming front. I have read somewhere you start with end float (measured with dti)
i.e if you wanted 3thou preload and had 7thou end float you'd fit 10thou shim?
To be honest I haven't really looked into it that much as I'm no where near that stage.

lynall said:

Good way to get bearing tracks out is to lay a bead of weld on the track itself as it cools its shrinks, obviously if you want to use the bearing again its a no go!

Must type faster!

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That's the plan if I have to.

uncoated last the longest imo, yes thats how preloads can be achieve ,your g/box wants between 0 and 2 thou preload no free play

jamesmartin said:

uncoated last the longest imo, yes thats how preloads can be achieve ,your g/box wants between 0 and 2 thou preload no free play

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Ah, Cheers for the info r.e pre-load. No doubt it wont go as simple as it sounds but it's a start
I think I've got uncoated coming so that's good

Managed to get the casing cleaned up and painted today.
Looks a darn sight better than it did anyway.

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Painted in 2k epoxy primer. Bloody good stuff but not cheap. Luckily I had some from another job (painted engine)

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Then painted in 2k satin black.
No pics as as soon as I was done someone came to pick some seats up. Got talking about 6bt conversion and was dark by the time he left
Also got a text today to say my delivery will be here tomorrow so hopefully it's what I want
Which is good and bad news as I still haven't tried getting the other bearings off.
Oh, I also prepped and primed a diff casing. Another job on the to do list.
After the gearbox but painted it now so I didn't have to get the gun out twice.

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Pictures from last night, Casing painted in 2k satin black.

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And a diff casing.

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Also as I sold some seats and had a spare bit of cash I bought this set

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And just like that Easy when you have the right tools for the job.

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Box of bits has also just turned up while I was writing this too. How far I'll get I don't know.
Probably not very to be honest. Half way through cleaning the extension casing up at the mo.

Aaron have you got a link for the blind bearing puller kit?

lynall said:

Aaron have you got a link for the blind bearing puller kit?

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Yep, cheapest I could find, But actually seems good quality

16 PCS PIECE BEARING REMOVER BRUSHES PULLER TEN COLLECTS INTERNAL BLIND POPULAR | eBay

So the rest of today's progress. Not sure if I got done as much as I thought I would or not. But progress non the less and it's not like I've got anything else to do.

So first job was to clean the extension casing up.
Again it's not perfect but a darn sight better than it was.
A parts washer or dish washer would be nice at this point

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Box of bits arrived.

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Cleaned and assembled one end of main shaft including new baulk rings and bearing pressed on the end.

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And the other end. I think it's all right anyway

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Managed to get the remaining bearings off. They got damaged in the process but that doesn't really matter seen as new ones have been fitted.

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Built it back up into center plate.
Of all the things on this job, The thing that scares me the most is the selectors They're probably really easy to be fair but I just make them complicated in my head.

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And then stuck the main casing on with a new gasket inbetween and bolted up.
Is it worth putting silicone inbetween the two?
I assume it'll affect the original pre-loading but if it's reset anyway is it worth doing.

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