dickie wrote:Failed at building the box.
Couldn't get a thin enough shim. Tried down to 1.6mm and it just locked it.
Original layshaft, case and endplate. New hub bearing (mb type with extra seal).
Tried 3 different gearboxes, all the same.
Checked bearing dimensions against an old one from a 64 LI and no difference.
Bearing and layshaft pulled fully home; checked a dozen times.
I measured face to face from an old LI layshaft versus the GP one I'm using and the GP one is 0.8mm longer, which would explain it.
However, I can't get my head round the fact that it's been in that motor for 30+ years.
I could use the old LI one but the splines are a bit iffy.
Got cold and I needed to get the timing set right on my other one, so I threw the towel in.
I'll try the old layshaft to prove a point if nothing else.
It's a bit disappointing as I'd hoped to get it on the dyno while I was there. Oh well.
From a safety aspect, I hope you are aware of the failures acociated with MB hub bearings fitted with non metallic cages. My own experiences with setting up gearboxes means that I have acquired loads of shims, many of intermediary sizes created by cleaning up old shims on a surface grinder. I check even brand new shims & engrave the actual size on each, & keep them in size order.
I also assemble just the loose gears for shimming purposes & only add the cluster when the target is achieved. Three thou" & no variation.....
However, I also have several end plates & their press fit bearing journals, (or housings).They can vary considerably, but all OEM Innocenti, Eibar & SIL seem to interchange.
I suspect the problem you experience is due to a bearing housing moving within the endplate. I've experienced this problem, so tend to press them out (a good vice will do it) clean the outer up along with the endplate bore using Scotchbrite pads, & press them back in with Loctite to prevent them moving again. (They will still press out if required)
In fact, with a good selection of shims, end plates & their bearing housings, I can claim to always achieve three thou" which is the optimum for conventional four speed boxes.
I hope my explanation is understandable & helps
I laid the beating down flat, spaced the balls out and refitted the plastic 'cage' and carried on to build the motor. I subsequently heard of instances where this cage had come out on its own in running motors - the motor is now out and awaiting me getting round to replacing that bearing.
