1970 s2 0453R Reassembly

[dakazman]

 JB, Another seal on order from RD, I'm also going to install the backup gearbox I picked up from a guy in California. The reasoning is because I found more aluminum shavings ( still to be determined), after draining the gearbox only after 4 miles. It will also give me a idea of what I purchased. The gear lash was higher than recommended but not by much, as much as I can remember anyway. WTS, I'll tear into the "original gearbox" further than where I left off. Rather do it no and repair something that hasn't exploded. I post its disassembly.
  Also remember, this is the gearbox that the primary shaft splits off with no roll pin hole on the front side and no evidence of it per manual. 
 Track Day at Daytona set for August 1st still. Wife is very nervous with that entire plan, but I hope to calm her down and listen to her concerns. I'm not racing just going around a track in line with Professionals , HOPEFULLY.
 Still have to get in and put on my helmet.
Dakazman
 
 

[dakazman]

  I transferred over parts from my gearbox to the spare, one hole needs to be upsized, but I’ll put that aside for now.
 I started the dissembling process. This is my first endeavor into a gearbox.  Found no catastrophic damage but I do have concerns about the primary shaft bearings. The front and rear move out of there races and the rear outer looks like it may be spinning.  The first 10 seconds show the float.

https://youtube.com/shorts/3C5JRETKRRA?si=EMx60wC0a_dwPm87

  Other miscellaneous pictures included for  any other advice you may want to give me.

[BDA]

I couldn't find anything in the parts or workshop manuals that would keep that shaft from walking like your video shows but I would think there would be SOMETHING!! On my NG3, the 5th gear goes there but you only have 4... I would look at the end of that primary shaft (where something should be present to keep the shaft from walking) area of the case for wear for the source of those aluminum shavings.

[jbcollier]

It is hard to tell for sure what with not being there.  You do not have a pinned input shaft so someone has been in there before you.  Just changed parts?  Got another transaxle?  Who knows.

http://lotus-europa.com/manuals/s2parts/f/fd.htm

This shows the stock set up.  The input shaft is located by the rear tapered roller bearing.  The bearing itself is located by a spacer and shim.  So, yes, your input shaft is free to slide about with the rear cover off.

[314159td]

The output bearing races look shot from here (the dull band between the shiny edges), I would plan on replacing them now or be forced to in a few thousand miles. Very likely the others are gone as well; mine were.

[dakazman]

  JB,
   I remember your concern about that input shaft not being pinned maybe a year ago.
   I'll post more pics, but it seems that the coupler is on the aft side of the primary shaft. Not at all what the manual shows. I'm in the parts manual learning all the nomenclature
so forgive me if I'm rambling about it. I could drill a hole in the forward primary shaft thru the coupling as an addition.
  I'm just wrapping my head around someone drilling thru the aft primary to fit the coupling there.  The parts shows the coupling on the input shat but the tension pin #5 more aft , so someone could have drilled it . It definitely is attached to it now but has a little play in the primary side and not thru the coupling.
   A few other books show,352/354 in the sectional the roll pin in the primary shaft but what I believe for part clarity on the input shaft . so I'm still looking for a sectional view on the 336.
  I did find the reason for the slop in the bearings the #8- retaining ring fell out , so you were correct about that movement for sure.
  Can this # 3 bearing 046 f 6051 be purchased ? Do you recommend it. What else should I change out, or replace while in here?
 I got a lot more reading to do.
 
  Thanks 314159td will do.

 Dakazman 

[jbcollier]

I’m glad to see you have the Renault manuals.  They are light years better than the Lotus manual.  Look at the bearings races to see if they need changing.

[BDA]

My vote to change all the bearings and seals anyway.

[dakazman]

   Guys, Consider it done.  Where are most parts found?
  I noticed the parts manual says I should have yellow synchros. Where are the colors found so I can verify.
  JB , yes the lotus manuals are hard to read , sometimes with letters missing on  an entire paragraph, okay maybe not that bad. The Renault books are very legible and detailed.
  My seal should show up tomorrow for the housing, even though I removed it and reinstalled. Not going to guess so it’s gone.  I’ll be installing the spare  gearbox , I need to know its weaknesses so I’m not just pushing it around my garage thinking it’s a true spare.
   Dave

 
 

[BDA]

renault16shop.com probably has everything you need and if they don’t have something, 123bearing.com would probably have it.

[TurboFource]

So all the torque from the engine is being handled by one little pin in the input shaft

[314159td]

So all the torque from the engine is being handled by one little pin in the input shaft

The coupler is splined on both ends, pin is just for retention

[TurboFource]

I see that now 

[Bainford]

 
  I noticed the parts manual says I should have yellow synchros. Where are the colors found so I can verify.
 

I am far from an expert on such things, but I think the reference to "yellow" synchros might be an indication they should be made of brass or a bronze material.

[dakazman]

  BDA , 321 has two bearings so far, one one aft primary measured 50 mm and it should be 52 mm. Other than that,  I can’t see anything else wrong. I’ll check what other items ( various shims) Renault 16 shop has . The grandkids came over so it was playtime.
 
  Bainford, I cleaned up the secondary and indeed it’s yellow paint on the synchros. I’m reading what a complete rebuild means in the manuals.
  Tomorrow I’ll be putting in the spare gearbox… with new seal that arrived today, Thanks RD.
 Dakazman