Update 2/2..
It's a nice change to just put something together, rather than make it entirely from scratch, and I enjoyed building the engine so much that I decided to rebuild the gearbox too!
Here's the first box full of bits.. thankfully I got a manual from Sadev, but as you'll see it wasn't the best.
First up was the primary shaft - nothing too complicated.
Then the secondary shaft - hmm..
The manual doesn't help much tbh.
Actually it's a fairly simple job, just repeating a sequence for 3 pairs of gears. Each one has an inner bearing race, a needle roller bearing, and the gear. Then between the two gears there's a dog ring and hub.
6th goes on first (above reverse) and has the race and bearing inside.
Then there's the dog ring, which engages the gear, and the hub which it slides along to select one of the pair.
And then on top of that goes the next gear, bearing, and race.
Repeat x 3.
Then the primary and secondary shaft go into the case, along with the gear selection barrel. Not a simple job, as the manual recommends heating the case to 120Deg before the secondary shaft will fit! I stuck the case in front of my space heater for an hour or so while assembling the shafts and thankfully it went in with little fuss!
That was all fairly simple tbh. What got me stuck was tightening up 2 bolts!
Both shafts are free to rotate in the box, and Sadev use a special tool to lock them which I don't have, so I had to make something up! The secondary is torqued up to 180Nm, so it'd have to be something more substantial than a wedged screwdriver.
Here's my Heath Robinson solution to stopping the shafts turning - took a while to set up but worked nicely.
Last thing to do was assemble the diff. Again, really useful diagram. Thanks Sadev. :neutral:
Then I got a bit carried away and put the whole thing back together, so no more pics. Sorry! 😅