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 gearbox rebuild and upgrade

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brabay



Cabin : Club
Posts : 78
Join date : 2011-10-15

gearbox - gearbox rebuild and upgrade Empty
PostSubject: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptySat Sep 01, 2018 9:05 pm

we all know that the Brazilian gearbox internal parts are not as strong as German made, they do however have very good and  strong aluminium case and heavy duty steel side plates, big cv joints (and the German beetle gearbox that some of you have used in your brazibays is made out of magnesium much lighter but also much weaker material - not really suitable for heavy van) so it make sense to rebuild them and replace all the weak components - the gears, bearings shift forks etc with best quality German ones.  

So this is what I have done with this one,  it arrived bit worse for wear:
gearbox - gearbox rebuild and upgrade 1
gearbox - gearbox rebuild and upgrade 2

dismantling the donor the get all the gears and then reassembling the pinion shaft:
 gearbox - gearbox rebuild and upgrade 4
 gearbox - gearbox rebuild and upgrade 5
 gearbox - gearbox rebuild and upgrade 6
 gearbox - gearbox rebuild and upgrade 7

dismantling the mainshaft
 gearbox - gearbox rebuild and upgrade 8
 gearbox - gearbox rebuild and upgrade 9

mainshaft bearing spacer the top one is brazilian - already badly worn out
 gearbox - gearbox rebuild and upgrade 10
mainshaft bearing brazi on the left:
 gearbox - gearbox rebuild and upgrade 11
pressing the bearing in:
 gearbox - gearbox rebuild and upgrade 12
 gearbox - gearbox rebuild and upgrade 13
 gearbox - gearbox rebuild and upgrade 14
German steel forks vs brazi brass ones, guess which ones are stronger and more durable:
 gearbox - gearbox rebuild and upgrade 15
Shift fork adjustment - thats a critical step without it it will not hold in the gear:
 gearbox - gearbox rebuild and upgrade 16
 gearbox - gearbox rebuild and upgrade 17
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 gearbox - gearbox rebuild and upgrade 20

here you can see aqua electronic speedo drive:
 gearbox - gearbox rebuild and upgrade 21


Last edited by brabay on Sun Sep 02, 2018 2:41 pm; edited 2 times in total
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dazdub

dazdub

Cabin : Exec 012
Location : wales
Posts : 2911
Join date : 2009-10-16

gearbox - gearbox rebuild and upgrade Empty
PostSubject: Re: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptySun Sep 02, 2018 7:40 am

Top job Smile
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gordonmac

gordonmac

Cabin : Exec 029
Location : Glasgow
Posts : 417
Join date : 2013-03-19

gearbox - gearbox rebuild and upgrade Empty
PostSubject: Re: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptySun Sep 02, 2018 12:04 pm

Looks good - how much does it improve the gear change?
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brabay



Cabin : Club
Posts : 78
Join date : 2011-10-15

gearbox - gearbox rebuild and upgrade Empty
PostSubject: Re: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptySun Sep 02, 2018 2:29 pm

@gordonmac wrote:
Looks good - how much does it improve the gear change?
what sort of problem with gear change you have?
gear change can be affected by several things such as wear in the gearbox - mostly the brass forks bend, crack or brake, gear engagement teeth and sliders wear off as well as synchronisers, bearings wear of allowing the shafts to move back and forth, but also linkage bushing are responsible for vague gear change.
so if you can be more specific please.
Also there seem to be much more damage to gearboxes on hire vehicles - I guess the reason is loads of drivers who have no experience and sympathy for old (design) vehicles.
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gordonmac

gordonmac

Cabin : Exec 029
Location : Glasgow
Posts : 417
Join date : 2013-03-19

gearbox - gearbox rebuild and upgrade Empty
PostSubject: Re: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptySun Sep 02, 2018 9:47 pm

Issue with mine is its sticky and stiff to change gears - first is particularly difficult to get into. Sometimes have to be v delicate and other times a bit more forceful. The castrol does help a bit.

I couldn't et anyone else drive it cos of the gears (and don't rent out either). Mine is air-cooled too BTW.
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brabay



Cabin : Club
Posts : 78
Join date : 2011-10-15

gearbox - gearbox rebuild and upgrade Empty
PostSubject: Re: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptySun Sep 02, 2018 11:01 pm

@gordonmac wrote:
Issue with mine is its sticky and stiff to change gears - first is particularly difficult to get into. Sometimes have to be v delicate and other times a bit more forceful. The castrol does help a bit.

I couldn't et anyone else drive it cos of the gears (and don't rent out either). Mine is air-cooled too BTW.
form what ive seen first gear always have badly rounded teeth also damaged fork could make things worse. but its always a guess until you open it.
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TimV
Admin
TimV

Cabin : Flight 001
Location : Brighton, East Sussex U.K.
Posts : 13750
Join date : 2009-09-27

gearbox - gearbox rebuild and upgrade Empty
PostSubject: Re: gearbox rebuild and upgrade   gearbox - gearbox rebuild and upgrade EmptyMon Sep 03, 2018 10:03 am

Great work @brabay!

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gearbox - gearbox rebuild and upgrade Melogo11
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