Countershaft install problem - Help!

 

The clustergear/countergear is all loaded up with the needle bearings and washers, and the cluster shaft spacer, and is sitting in the bottom of the case. The thrust washers are all installed in the case on the ends. The countershaft has gone in from the back just fine and is right at the point where it wants to locate in the front of the case. I can see the end. It has cleared all the thrust washers. It has less than half an inch to go.

 

My problem is that it just won't go in the last bit. I am able to lift the cluster gear to make sure that the shaft is aligning properly with the front hole, but it won't go. I have tried tapping with a plastic hammer, and also with a brass drift. But I don't want to hit too hard for fear of damaging something.

 

1. How hard should I have to hit?

2. Has anyone ever had a problem with the countershaft install from Novak?

3. Anything else I should be trying?

 

There was a very, very slight shoulder at the lock plate end of the Novak countershaft. Too small to even measure, but large enough to feel with your finger. My gut feel is that this is stopping the shaft from going in the rear hole. But surely they wouldn't sell a shaft that doesn't fit? And if they did others would have had the same problem as me? The last thing I want to do is to start modifying my brand new specially hardened countershaft to get it to fit.

 

Please help!

 

Mike

19.20mm on the shaft

19.35mm on the shoulder.

 

In inches that's 0.7559" on the shaft.

0.7618" on the shoulder.

 

That's 0.0059" difference, or less than 6 thousandths of an inch.

 

Should I try to take this shoulder off? Should there even be a shoulder?

 

Mike

 

 

Do all shafts have this shoulder, or just the Novak one?

 

I would be interested if anyone has had a similar experience with the Novak shaft lately...

 

After sanding the shoulder down to fit, I finished up the rebuild of the T90. I'm pretty pleased with the outcome.

 

 

 

I had trouble shifting from second to third by hand, but a search of this forum says that this is often stiff, and seems to be easier when the transmission is installed, full of oil, and the shift lever provides some mechanical advantage into the shift fork. Nothing is binding up and it all turns freely by hand, so I'm going to trust that it will all be good when installed!

 

I am left with an additional snap ring from the Novaks rebuild kit I ordered.

 

 

It has an ID of 1.4429", OD of 1.7657" and thickness of 0.0945". There are only two of these SMALLER type snap rings that I can find on any exploded parts list - the front input shaft bearing retainer, and the clutch hub to mainshaft retainer. These are both on.

 

1. Anyone have experience of this same kit from Novak, and also end up with a "spare" snap ring?

2. Would it possibly be used if you had an overdrive?

 

It is always disconcerting when you finish a rebuild and have parts left over! I am looking for some comfort that I haven't overlooked anything on the rebuild!

 

Thanks!